1452 Tech Spec

TENDER SPECIFICATION
BHEL: PSSR: SCT: 1452

FOR
Handling at Site Store / Storage Yard, Transportation to Site of Work, Erection, Testing and Commissioning of 3 Nos. Frame 9E Gas Turbine, Generator and its Auxiliaries, 2 Nos. of 30 MW Steam Turbine, Generators and their Auxiliaries, including integral piping and insulation, and Balance of Plant Equipment, including Supply and Application of Final Painting.
at IOCL- PARADIP REFINARY PROJECT 366MW CO-GENERATION CPP PACKAGE Paradip, Orissa
VOLUME I BOOK - I
TECHNOCOMMERCIAL BID (Book I & II) Book-I consists of o Notice Inviting Tender, o Volume-IA : Technical Conditions of Contract Book-II consists of o Volume-IB : Special conditions of Contract, o Volume-IC : General conditions of Contract o Volume-ID : Forms & Procedures
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking) Power Sector Southern Region 690, Anna Salai, Nandanam, Chennai 600 035.
BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking) Power Sector, Southern Region 690, Anna Salai, Nandanam, Chennai 35
Tender Specification No. BHEL: PSSR: SCT: 1452 for Handling at Site Store / Storage Yard, Transportation to Site of Work, Erection, Testing and Commissioning of 3 Nos. Frame 9E Gas Turbine, Generator and its Auxiliaries, 2 Nos. of 30 MW Steam Turbine, Generators and their Auxiliaries, including integral piping and insulation, and Balance of Plant Equipment, including Supply and Application of Final Painting at IOCL- Paradip Refinery Project, 366MW Co-generation CPP Package, Paradip, Orissa One set of Tender documents consisting of 1) TECHNOCOMMERCIAL BID - 2 copies 2) PRICE BID - 2 copies Book Sl no . Issued to M/s
Refer NIT for Last date of submission Please note this tender document is not transferable For and on behalf of BHARAT HEAVY ELECTRICALS LIMITED
ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35 Date:
Rev 00 6th July 2010
NOTICE INVITING TENDER
Bharat Heavy Electricals Limited
Ref: BHEL PSSR SCT 1452
Date: Mar 17, 2011
NOTICE INVITING TENDER (NIT)

NOTE: BIDDER MAY DOWNLOAD FROM WEB SITES OR PURCHASE TENDERS FROM THIS OFFICE ALSO
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To
Dear Sir / Madam Sub : NOTICE INVITING TENDER Sealed offers in two part bid system are invited for the subject job by the undersigned on the behalf of BHARAT HEAVY ELECTRICALS LIMITED as per the tender document. Following points relevant to the tender may please be noted and complied with. 1.0
Sl. No
Salient Features of NIT ISSUE TENDER NUMBER Broad Scope of job BHEL PSSR SCT 1452
DESCRIPTION
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Handling at Site Store / Storage Yard, Transportation to Site of Work, Erection, Testing and Commissioning of 3 Nos. Frame 9E Gas Turbine, Generator and its Auxiliaries, 2 Nos. of 30 MW Steam Turbine, Generators and their Auxiliaries, including integral piping and insulation, and Balance of Plant Equipment, including Supply and Application of Final Painting at IOCL- Paradip Refinery Project, 366MW Cogeneration CPP Package, Paradip, Orissa DETAILS OF TENDER DOCUMENT Volume-IA Technical Conditions of Contract (TCC) consisting of Scope of work, Technical Specification, Drawings, Applicable Procedures, Bill of Quantities, Terms of payment, etc Volume-IB Special Conditions of Contract (SCC) Applicable Volume-IC General Conditions of Contract (GCC) Applicable Volume-ID Forms and Procedures Applicable Volume-II Price Schedule (Absolute value). Applicable Issue of 1.Sale from BHEL PSSR Regional office at Tender :Chennai Applicable Documents Start : Mar 21, 2011 Closes: Apr 11, 2011 , Time :15.00 Hrs
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2.From BHEL website (www.bhel.com) Tender documents can however be downloaded from website till due date of submission DUE DATE & Date : Apr 12, 2011, Time :15.00Hrs Applicable TIME OF Place : BHEL PSSR :Chennai OFFER Tenders can be submitted through representative / in SUBMISSION person at SCT Dept, BHEL PSSR, Chennai. OPENING OF Date : Apr 12, 2011, Time :15.30Hrs Applicable TENDER Notes: (1) In case the due date of opening of tender becomes a non-working day, tenders shall be opened on next working day at the same time. (2) Bidder may depute representative to witness the opening of tender EMD Applicable Rs 2,00,000/- (Rupees Two Lakhs Only) AMOUNT COST OF Rs 2000/-. Applicable TENDER LAST DATE At least 7 days before the due date of offer submission FOR or two days before the scheduled date of pre-bid Applicable SEEKING meeting whichever is earlier CLARIFICATI Along with soft version also, addressing to undersigned ON & to others as per contact address given below SCHEDULE Date: Mar 31, 2011. Time 10.00AM OF Pre Bid at BHEL:PSSR:Chennai-35 Applicable Discussion (PBD) INTEGRITY Bidders shall enter into an Integrity Pact (IP) with Not PACT & BHEL as per format given at Volume 1D Formats of Applicable DETAILS OF this tender. The bidders are required to return this INDEPENDEN Integrity Pact (IP) along with Techno Commercial Bid T EXTERNAL duly signed and stamped by the authorized signatory MONITOR who signs the bid. It may be noted that only those (IEM) bidders who have entered into such an IP with BHEL would be competent to participate against this tender .i.e. entering into this pact is a preliminary qualifications for the bidders. The Independent External Monitor against this NIT shall be Shri ...
xii Latest updates
Latest updates on the important dates, Amendments, Correspondences, Corrigenda, Clarifications, Changes, Errata, Modifications, Revisions, etc to Tender Specifications will be hosted in BHEL webpage (www.bhel.com Tender Notifications View Corrigendums) and not in the newspapers. Bidders to keep themselves updated with all such information
2.0
The offer shall be submitted as per the instructions of tender document and as detailed in this NIT. Bidders to note specifically that all pages of tender document, including these NIT pages of this particular tender together with subsequent correspondences shall be submitted by them, duly signed & stamped on each page, as part of offer. Rates / Price including discounts / rebates, if any, mentioned anywhere/in any form in the techno-commercial offer other than the Price Bid, shall not be entertained. Unless specifically stated otherwise, bidder shall remit cost of tender and courier charges if applicable, in the form of Demand Draft drawn in favour of Bharat Heavy Electricals Ltd, payable at Power Sector Regional HQ at Chennai issuing the Tender, along with techno-commercial offer. Bidder may also choose to deposit the Tender document cost by cash at the Cash Office as stated above against sl no iv of 1, on any working day; and in such case copy of Cash receipt is to be enclosed with the Techno Commercial offer. Sale of tender Documents shall not take place on National Holidays, holidays declared by Central or State Governments and BHEL PS HQ at Chennai, Sundays and second/ last Saturdays Unless specifically stated otherwise, bidder shall deposit EMD through Demand Draft/Pay Order in favour of Bharat Heavy Electricals Ltd, payable at Chennai. For other details and for One Time EMD please refer General Conditions of Contract. Procedure for Submission of Tenders: The Tenderers must submit their Tenders to Officer inviting Tender, as detailed below: PART-I consisting of PART-I A (Techno Commercial Bid) & PART-I B (EMD/COST of TENDER) in two separate sealed and superscribed envelopes (ENVELOPE-I & ENVELOPE-II) PART-II(Price Bid) in sealed and superscribed envelope (ENVELOPE-III) One set of each document shall be retained by the bidder for their reference.
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6.0 Sl no
The contents for ENVELOPES and the superscription for each sealed cover / Envelope are as given below. (All pages to be signed and stamped) Description Part-I A ENVELOPE I superscribed as : PART-I (TECHNO COMMERCIAL BID) TENDER NO : NAME OF WORK : PROJECT: DUE DATE OF SUBMISSION: Remar ks
CONTAINING THE FOLLOWING:i. Covering letter/Offer forwarding letter of Tenderer. ii. Duly filled-in `No Deviation Certificate' as per prescribed format to be placed after document under sl no (i) above. Note: a. In case of any deviation, the same should be submitted separately for technical & commercial parts, indicating respective clauses of tender against which deviation is taken by bidder. The list of such deviation shall be placed after document under sl no (i) above. It shall be specifically noted that deviation recorded elsewhere shall not be entertained. BHEL reserves the right to accept / reject the deviations without assigning any reasons, and BHEL decision is final and binding. c. In case of acceptance of the deviations, appropriate loading shall be done by BHEL (ii) In case of unacceptable deviations, BHEL reserves the right to reject the tender. iii. Supporting documents / annexure / schedules / drawing etc as required in line with Pre-Qualification criteria. It shall be specifically noted that all documents as per above shall be indexed properly and credential certificates issued by clients shall distinctly bear the name of organization, contact ph no, FAX no, etc. iv. All Amendments / Correspondences / Corrigenda / Clarifications / Changes / Errata etc pertinent to this NIT. v. Integrity Pact Agreement (Duly signed by the authorized signatory) If appli cable vi. Duly filled-in annexures, formats etc as required under this Tender Specification/NIT vii. Notice inviting Tender (NIT) b.
viii. Volume I A : Technical Conditions of Contract (TCC) consisting of Scope of work, Technical Specification, Drawings, Procedures, Bill of Quantities, Terms of payment, etc ix. Volume I B : Special Conditions of Contract (SCC) x. Volume I C : General Conditions of Contract (GCC) xi. Volume I D : Forms & Procedures xii. Volume II (UNPRICED without disclosing rates / price, but mentioning only QUOTED or UNQUOTED against each item xiii. Any other details preferred by bidder with proper indexing. PART-I B ENVELOPE II superscribed as: PART-I (EMD/COST of TENDER) TENDER NO : NAME OF WORK : PROJECT: DUE DATE OF SUBMISSION: i. CONTAINING THE FOLLOWING:1. Earnest Money Deposit (EMD) in the form as indicated in this Tender OR Documentary evidence for One Time EMD with BHEL PSSR Chennai 2. Cost of Tender (Demand Draft or copy of Cash Receipt as the case may be) PART-II PRICE BID consisting of the following shall be enclosed ENVELOPE-III superscribed as: PART-II (PRICE BID) TENDER NO : NAME OF WORK : PROJECT: DUE DATE OF SUBMISSION: CONTAINING THE FOLLOWING Covering letter/Offer forwarding letter of Tenderer enclosed in Part-I Volume II PRICE BID ( Duly Filled in Schedule of Rates rate/price to be entered in words as well as figures)
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OUTER COVER ENVELOPE-IV (MAIN ENVELOPE / OUTER ENVELOPE) superscribed as: TECHNO-COMMERCIAL BID, PRICE BID & EMD TENDER NO: NAME OF WORK: PROJECT: DUE DATE OF SUBMISSION: i CONTAINING THE FOLLOWING: o Envelopes I o Envelopes II o Envelopes III SPECIAL NOTE: All documents/ annexures submitted with the offer shall be properly annexed and placed in respective places of the offer as per enclosure list mentioned in the covering letter. BHEL shall not be responsible for any missing documents. 7.0 No Deviation with respect to tender clauses and no additional clauses/ suggestions/ in Techno-commercial bid/ Price bid shall normally be considered by BHEL. Bidders are requested to positively comply with the same. BHEL reserves the right to accept or reject any or all Offers without assigning any reasons thereof. BHEL also reserves the right to cancel the Tender wholly or partly without assigning any reason thereof. Also BHEL shall not entertain any correspondence from bidders in this matter (except for the refund of EMD). Assessment of Capacity of Bidders: (Shall be applicable for all Bid Evaluation from 1st April 2011) Bidders capacity for executing the job under tender shall be assessed as per the following: I. Assigning Weightages (A) for Similar Jobs Under-Execution: Weightages shall be worked out and assigned based on the average number of Similar Works under execution including works yet to be commenced by the agency, in the following manner: i). Number of Similar Jobs a) No. of jobs in BHEL, PSER b) No. of jobs in BHEL, PSSR c) No. of jobs in BHEL, PSWR d) No. of jobs in BHEL, PSNR e) No. of jobs with other customers* Say J Say K Say L Say M Say N (*: Other than BHEL PSER, PSSR, PSWR & PSNR) f) Average No. of Jobs is P= (J+K+L+M+N) divided by 5 : : : : :
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ii) Weightage A assigned to bidders based on Average Number of jobs P; a)If P = 0-1, A will be equal to 3 b)If P = 2-3, A will be equal to 2 c)If P = 4-5, A will be equal to 1 d)If P is Above 5, A will be equal to 0 II. Weightage B for Quarterly Performance Reports of Vendors: This shall be based on the averages of the net weighted score obtained by the bidder for the jobs under execution (excluding works not commenced) for the quarter previous to the last quarter reckoned from the date of latest due date of submission, in all four Regions i.e BHEL PSER, PSSR, PSWR & PSNR, in the following manner. i). Ratings by Power Sector Region: a)PS ERs Rating Rer = (X1 + X2 + .. + Xn) b)PS WRs Rating Rwr = (X1 + X2 + .. + Xn) c)PS SRs Rating Rsr = (X1 + X2 + .. + Xn) d)PS NRs Rating Rnr = (X1 + X2 + .. + Xn) e)Over all Power Sector Region Rating RBHEL= (Rer+ Rwr+ Rsr+ Rnr) divided by (Ner+ Nwr+ Nsr+ Nnr) (where X1, X2, X3,Xn is the net weighted score obtained by the bidder as per the Evaluation of Contractor Performance (Quarterly) against the various contracts n under execution in the respective Region). ii) Weightage B assigned to bidders based on Overall Power Sector Rating (RBHEL): a)If RBHEL is 80% and above, B will be equal to 6 b)If RBHEL is > 70% < 80%, B will be equal to 5 c) If RBHEL is > 60% < 70%, B will be equal to 4 d) If RBHEL is = < 60%, B will be equal to 0 III. Evaluation of Bidders capacity to execute the job under tender: shall be based on the sum of scores obtained in A and B, as below: a) 6 or above : Considered Qualified for the job under tender b) Less than 6: Considered NOT Qualified for the job under tender IV. Explanatory note: a) Similar work means Boiler or Turbine or Civil or Electrical or CI, etc as detailed in the scope irrespective of rating of Plant. b) Quarter shall be as per the quarter defined in the Evaluation of Contractor performance (Quarterly). For contracts where annexed Quarterly Evaluation performance was not part of the contract, Quarterly Performance Reports
previous to the last quarter reckoned from the date of latest due date of submission, given by the respective project site against the contract will be the basis for evaluation. c) Vendors who are not executing any jobs presently in the Region and first timers to the Region, may be considered subject to satisfying all other tender conditions d) Under execution shall mean works in progress upto Boiler Steam Blowing (for Boiler and Auxilliaries) or Synchronisation (for all other jobs including Civil) shall be considered. 10.0 Since the job shall be executed at site, bidders must visit site/ work area and study the job content, facilities available, availability of materials, prevailing site conditions including law & order situation etc before quoting for this tender. They may also consult this office before submitting their offers, for any clarifications regarding scope of work, facilities available at sites or on terms and conditions. No additional claim shall be entertained by BHEL in future, on account of nonacquaintance of above. 11.0 For any clarification on the tender document, the bidder may seek the same in writing or through e-mail, as per specified format, within the scheduled date for seeking clarification, from the office of the undersigned. BHEL shall not be responsible for receipt of queries after due date of seeking clarification due to postal delay or any other delays. Any clarification / query received after last date for seeking clarification may not be normally entertained by BHEL and no time extension will be given. 12.0 BHEL may decide holding pre-bid discussion [PBD] with all intending bidders as per date indicated in the NIT. The bidder shall ensure participation for the same at the appointed time, date and place as may be decided by BHEL. Bidders shall plan their visit accordingly. The outcome of pre-bid discussion (PBD) shall also form part of tender. In the event of any conflict between requirement of any clause of this specification / documents / drawings / data sheets etc or requirements of different codes / standards specified, the same to be brought to the knowledge of BHEL in writing for clarification before due date of seeking clarification (whichever is applicable), otherwise, interpretation by BHEL shall prevail. Any typing error / missing pages / other clerical errors in the tender documents, noticed must be pointed out before pre-bid meeting / submission of offer, else BHELs interpretation shall prevail.
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14.0 Unless specifically mentioned otherwise, bidders quoted price shall deemed to be in compliance with tender including PBD. 15.0 Bidders shall submit Integrity Pact Agreement (Duly signed by authorized signatory who signs in the offer), if applicable, along with techno-commercial bid.
This pact shall be considered as a preliminary qualification for further participation. The names and other details of Independent External Monitor (IEM) for the subject tender is as given at point (xi) of 1 above. 16.0 The Bidder has to satisfy the Pre Qualifying Requirements stipulated for this Tender in order to be qualified. The Price Bids of only those bidders will be opened who will be qualified for the subject job on the basis of pre-qualification evaluation / techno-commercial bids, approval / acceptance of customer (as applicable), etc. and date of opening of price bids shall be intimated to only such bidders. 17.0 In case BHEL decides on a `Public Opening', the date & time of opening of the sealed PRICE BID shall be intimated to the qualified bidders and in such a case, bidder may depute one authorised representative to witness the price bid opening. BHEL reserves the right to open in-camera the PRICE BID of any or all Unsuccessful/Disqualified bidders under intimation to the respective bidders. 18.0 Validity of the offer shall be for six months from the latest due date of offer submission (including extension, if any) or specified otherwise in SCC of tender.
19.0 BHEL reserves the right to decide the successful bidder on the basis of Reverse Auction process. In such case all qualified bidders will be intimated regarding procedure/ modality for Reverse Auction process prior to Reverse Auction and price will be decided as per the rules for Reverse Auction. . However, if reverse auction process is unsuccessful as defined in the RA rules / procedures, or for whatsoever reason, then the sealed PRICE BIDs will be opened for deciding the successful bidder. BHELs decision in this regard will be final and binding on bidder. 20.0 On submission of offer, further consideration will be subject to compliance to tender & qualifying requirement and customers acceptance, as applicable. 21.0 In case the bidder is an Indian Agent of Foreign Principals, Agency agreement has to be submitted along with Bid, detailing the role of the agent along with the terms of payment for agency commission in INR, along with supporting documents. The bidders shall not enter into any undisclosed M.O.U. or any understanding amongst themselves with respect to tender. In case Consortium Bidding is allowed as per Pre Qualifying Requirement, then Prime Bidder and Consortium Partner shall enter into Consortium Agreement. Validity period of Consortium Agreement shall be 6 months after which the same can be re validated.
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Stand alone bidder cannot become a prime bidder or a consortium bidder in a consortium bidding. Prime bidder shall neither be a consortium partner to other prime bidder nor take any other consortium partners. However, consortium partner may enter into consortium agreement with other prime bidders. In case of non compliance, consortium bids of such Prime bidders will be rejected. . 24.0 The bidder shall submit documents in support of possession of Qualifying Requirements duly self certified and stamped by the authorized signatory, indexed and properly linked in the format for PQR. In case BHEL requires any other documents/proofs, these shall be submitted immediately. The bidder may have to produce original document for verification if so decided by BHEL. Mode of award of work for Block-A (GTG 1st & 3rd , STG-1st and BOP components-458.3 MT) and Block-B (GTG 2nd, STG- 2nd and BOP components458.7 MT)
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26.1 There are three nos of GTGs, two nos of STG and BOP components 917MT(Approx) at IOCL-Paradip refinery Project - 366MW, Paradip, Orissa. The tender BHEL:PSSR: SCT1452 consists of two Blocks i.e., Block- A & B. Block- A is for GTG 1st & 3rd , STG-1st and BOP components-458.3 MT. The total approx weight to be erected in Block A is 3181 MT. Block- B is for GTG 2nd, STG- 2nd and BOP components-458.7 MT. The total approx weight to be erected in Block B is 2010 MT. The quantity indicated in the price bid is for one GTG, one STG and BOP components-458.5MT (Approx). The work content of each of the GTG is same. The work content of each of the STG is same. The variation in the work content of the BOP components may be meager depending on the equipments. The equipment wise allocation of BOP components for Block A & B shown in weight schedule is only tentative. Actual allocation at site shall be decided by BHEL engineer according to technical feasibility. However the BOP components shall be distributed among blocks A & B so that each block shall have equal tonnage of BOP components. 26.2 The L1 bidder against this quote will be awarded the contract for Block- A {GTG 1st & 3rd, STG-1st and BOP components-458.3 MT (Approx)} only of IOCL-Paradip refinery Project - 366MW, Paradip. 26.3 BHEL reserves the right to award the contract for Block- B {GTG 2nd , STG- 2nd and BOP components-458.7 MT(Approx)} of IOCL-Paradip refinery Project 366MW, Paradip on the same terms and conditions of SCT 1452 to the next lowest bidder in the order of competitiveness who should match his rates with awarded rates for Block- A .
26.4 Thus the total work three nos of GTGs, two nos of STG and BOP components -917 MT (approx) will be awarded to two agencies i.e., two nos of GTGs, one no of STG & BOP components 458.3 MT (Approx) works for one agency and one no GTG, one no of STG & BOP components 458.7 MT (Approx) works for the next agency. 26.5 In case the other bidders in their order of competitiveness do not accept to match their rates with awarded rates of Block- A, then BHEL reserves the option to consider the L1 bidder, for award of Block-B work also at the same rates and at the same Terms & Conditions of Block-A. This will be solely at the discretion of BHEL and the L1 bidder, who is awarded the work of Block- A, shall not have any claim for award of Block- B work to him, on conditions whatsoever. 26.6 Incase BHEL, at its discretion opts to go for re-tendering for award of work for Block- B, then the L1 bidder who is awarded with Block-A work shall not be considered for Block-B work. 26.7 Each block will be treated as a separate contract. 27.0 Order of Precedence In the event of any ambiguity or conflict between the Tender Documents, the order of precedence shall be in the order below: a. Amendments / Clarifications / Corrigenda / Errata etc issued in respect of the tender documents by BHEL b. Notice Inviting Tender (NIT) c. Price Bid d. Technical Conditions of Contract (TCC)Volume-1A e. Special Conditions of Contract (SCC) Volume-1B f. General Conditions of Contract (GCC) Volume-1C g. Forms and Procedures Volume-1D For BHARAT HEAVY ELECTRICALS LTD AGM /SCT Enclosure 01. Annexure-1: Pre Qualifying criteria. 02. Annexure-2: Check List. 03 Other Tender documents as per this NIT.
ANNEXURE - 1 PRE QUALIFYING CRITERIA JOB Handling at Site Store / Storage Yard, Transportation to Site of Work, Erection, Testing and Commissioning of 3 Nos. Frame 9E Gas Turbine, Generator and its Auxiliaries, 2 Nos. of 30 MW Steam Turbine, Generators and their Auxiliaries, including integral piping and insulation, and Balance of Plant Equipment, including Supply and Application of Final Painting at IOCL- Paradip Refinery Project, 366MW Co-generation CPP Package, Paradip, Orissa
TENDER BHEL PSSR SCT 1452 NO Sl. No PRE QUALIFICATION CRITERIA A B Submission of Integrity Pact duly signed (if applicable) Assessment of Capacity of Bidder to execute the work as per sl no 9 of NIT (if applicable) Technical Bidders claim in respect of fulfilling the PQR Criteria Name and Page no of Description of supporting qualifying criteria document Not applicable Shall be applicable for Bid Evaluation from 1st April 2011
Refer Annexure-3 D 1 Financial TURNOVER Bidders must have achieved an average annual financial turnover (audited) of Rs 297 lakhs or more over last three financial years i.e., 2007-08, 2008-09 & 2009-10 D2 NETWORTH Net worth of the bidder based on the latest audited accounts as furnished for D1 above should be positive. D3 PROFIT Bidders must have earned profit in any one of the three financial years in the last three years defined in D1 above
D4 In case bidder submits offer with backup guarantor then the backup guarantor should also meet the financial criteria as furnished in D1,D2& D3 above E Approval of Customer (if applicable) Note: Names of bidders who stand qualified after compliance of criteria A to D shall be forwarded to customer for their approval. Price bid of only those bidders shall be opened who are approved by customer. F G Consortium criteria (if applicable) Notwithstanding the above, BHEL reserves the right to reject any or all the Tenders for reasons whatsoever beyond its control and the decision of BHEL is final. Applicable
Not applicable Applicable
Explanatory Notes for QR A 1.The word executed means the bidder should have achieved the criteria specified in the QR even if the total contract has not been completed or closed 2.Bidder to submit Audited Balance Sheet and Profit and Loss Account for the respective years as given above along with all annexures BIDDER SHALL SUBMIT ABOVE PRE-QUALIFICATION CRITERIA FORMAT, DULY FILLED-IN, SPECIFYING RESPECTIVE ANNEXURE NUMBER AGAINST EACH CRITERIA AND FURNISH RELEVANT DOCUMENT (copies of Work order / LOI / LOA and work completion certificate) IN THE RESPECTIVE ANNEXURES IN THEIR OFFER.
ANNEXURE - 2 CHECK LIST NOTE: - Tenderers are required to fill in the following details and no column should be left blank 1 Name and Address of the Tenderer 2 Details about type of the Firm / Company Details of Contact person for this Tender: Name : Mr / Ms Designation: 3a Telephone No: Mobile No: Fax No: E-mail ID: Details of alternate Contact person for this Tender: Name : Mr / Ms Designation: 3b Telephone No: Mobile No: Fax No: E-mail ID: EMD DETAILS 4 5 Validity of offer DD No: Date : Bank : Amount: Please tick ( ) whichever applicable:ONE TIME EMD / ONLY FOR THIS TENDER To be valid for six months from due date APPLICABILITY Whether the format for compliance with PRE QUALIFICATION CRITERIA (ANNEXURE-I) is Applicable / Not 6 understood and filled with proper supporting applicable documents referenced in the specified format 7 Audited profit and Loss Account for the last three years submitted Applicable / Not applicable Applicable / Not applicable BIDDER REPLY YES / NO
YES/NO YES/NO
8 Copy of PAN Card submitted
Whether all pages of the Tender documents Applicable / Not 9 including annexures, appendices etc are read applicable understood and signed Applicable / Not 10 Integrity Pact applicable Applicable / Not 11 Declaration by Authorised Signatory applicable Applicable / Not 12 No Deviation Certificate applicable 13 Declaration confirming knowledge about Site Conditions Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable Applicable / Not applicable
YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO
14 Declaration for relation in BHEL 15 Non Disclosure Certificate 16 Bank Account Details for E-Payment 16 Capacity Evaluation of Bidder for current Tender 17 18 Tie Ups / Consortium Agreement are submitted as per format Power of Attorney for Submission of Tender / Signing Contract Agreement
19 Analysis of Unit rates 20 Unquoted price bid submitted or not NOTE: STRIKE OFF YES OR NO, AS APPLICABLE
DATE: AUTHORISED SIGNATORY (With Name, Designation and Company seal)
ANNEXURE - 3 PRE QUALIFICATION CRITERIA -Technical: Bidder should have executed erection and commissioning of STG works of at least one unit of minimum 30MW, in any Power Plant in the last seven year preceding the scheduled date of Bid submission. The term Executed means the unit should have been synchronized. OR Bidder should have executed erection and commissioning of atleast one unit of Frame 6 GTG or mimimum one unit of 30MW capacity GTG in any Power Plant in the last seven year preceding the scheduled date of Bid submission. The term Executed means the unit should have been synchronized. OR Bidder should have executed erection and commissioning of one unit of Frame V GTG / minimum 15MW capacity GTG / minimum 15MW capacity STG, in any Plant in the last seven years preceding the scheduled date of Bid submission, subject to providing the security of a Backup Guarantor as per the enclosed format / tender requirements. The term Executed means the unit should have been synchronized. OR Bidder should have executed erection and commissioning of at least one unit of any one of the following three items, in any plant in the last seven year preceding the scheduled date of Bid submission, subject to providing the security of a Backup Guarantor as per the enclosed format / tender requirements 1) minimum rating 190MW Boiler / 570TPH Boiler 2) Chemical recovery Boiler of minimum rating 350 Tons of dry solids per day 3) HP piping of minimum rating 190MW in Power cycle piping package works. The term Executed means safety valve floating of the boiler should have been completed or the unit should have been synchronized. Backup Guarantor MUST a) have executed at least one unit STG of minimum 190 MW of BHEL make against order direct from BHEL, or one unit of Frame 9 GTG. b) furnish a BG in the prescribed format, direct to BHEL, valid for the duration of the tendered works and equivalent to 10% of the bid amount in a SEALED cover. c) also satisfy the assessment of Bidders capacity indicated for the Bidder in NIT and his performance in this project will also be assessed for loading purpose. d) furnish a certificate that he has not provided back up in this tender to any other agency for this package.
e) also satisfy the financial criteria indicated for the bidder. f) also attend the monthly reviews and be a joint signatory to monthly evaluation of progress. g) function with the spirit of ensuring the performance of the bidder for successful completion of the scope of the works tendered. h) On Completion of works, the experience of subject execution will be assigned to the bidder on whom the award has been placed. This bidder will be treated as eligible for the next higher group on his own strength.
TECHNICAL CONDITIONS OF CONTRACT (TCC)

Rev 00 6th July 2010
VOLUME IA Part I & II TECHNICAL CONDITIONS OF CONTRACT (TCC)

(Document No PS:MSX:TCC)
BHARAT HEAVY ELECTRICALS LIMITED

Technical Conditions of Contract (Document no PS:MSC:TCC, Rev 00, 6th July 2010)
TECHNICAL CONDITIONS OF CONTRACT (TCC) CONTENTS

Sl no Vol IA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Vol IA 1 2 3 4 5 6 7 Vol IA 1 2 DESCRIPTION Volume -I Part-I: Contract specific details Project Information Scope of works Facilities in the scope of Contractor / BHEL (Scope Matrix) T&Ps and MMEs to be deployed by Contractor T&Ps and MMEs to be deployed by BHEL on sharing basis Time Schedule Terms of Payment Taxes and other Duties Weight schedule General Foundation & Grouting Handling & storage Erection Progress of work Welding Testing & Commissioning Painting Part-II: Technical specifications Reverse auction procedure Site weld data Insulation schedule Insulation volume Weight schedule-item wise Weight schedule material wise Job specification for shop & Field Painting Part-III: Forms for back up guarantor Back up guarantee agreement Decleration Chapter-I Chapter-II Chapter-III Chapter-IV Chapter-V Chapter-VI Chapter-VII Chapter-VIII Chapter-IX Chapter-X Chapter-XI Chapter-XII Chapter-XIII Chapter-XIV Chapter-XV Chapter-XVI Chapter-XVII Chapter-1 Chapter-2 Chapter-3 Chapter-4 Chapter-5 Chapter-6 Chapter-7 Chapter-1 Chapter-2 01 02 06 02 02 02 04 02 13 03 02 01 08 02 02 07 02 02 01 03 01 01 01 60 03 02 Chapter No. of Pages

VOLUME- I A PART I CHAPTER I PROJECT INFORMATION
1 2 3 4 5 6 7 8 9 10 11 12 13 Name of the Project Station Capacity Owner Consultant Site Location Latitude Longitude MSL Nearest Highway Nearest Town / City Nearest Railway Station Nearest Air port Metrological Data A) Temperature i. Average Max Temperature ii. Average Min Temperature iii. Highest Max Temperature iv. Lowest Minimum Temperature v. Temperature to be considered for design of Electrical Equipments / Devices B) Relative Humidity average C) Rainfall ( Average Annual ) D) Wind Data Summer Wind Data Winter Wind Data Cyclone Basic Wind speed for structural design E) Seismic Data Languages spoken in the region Language for communication with Sub- Contractor / Vendors Tropicalisation Supply Voltage IOCL PARADIP 366MW COGENERATION CPP PACKAGE 366 MW M/s Indian oil Corporation Ltd M/s EIL IOCL Paradip Refinery Project, Paradip Port Post, Orissa 754 141 20 Degrees 15 20 86 Degrees 26 00 3.91 IMSL 5A Paradip Paradip Bhubaneshwar 37 Deg C 16 Deg C 42.4 Deg C 11.3 Deg C 50 Deg C 99.7% Heavy 37-45 km/hr 15-26 km/hr 200-250 km/hr (S-SE) 65 m/sec Zone III English, Odiya English All Equipments supplied against this specification shall be given tropical and fungicidal treatment in view of climatic conditions prevailing at site 3 Phase 415 Volts
14 15 16 17

VOLUME- I A PART I CHAPTER II
SCOPE OF WORKS The scope of the work will comprise of but not limited to the following: 1.2.1.1 Receipt of materials / component to be erected by the contractor, loading and transportation from the storage yard to the project site, stacking, storage and preservation. 1.2.1.2 Preassembly, Erection, Testing, Commissioning, Trial operation and reliability operation of equipment. 1.2.1.3 Final painting including supply of paints. 1.2.1.4 Arranging temporary piping, equipment for Hydro Test, chemical cleaning, steam blowing etc. Supply of chemicals during commissioning will be by BHEL. 1.2.1.5 Assisting BHEL in getting statutory approvals at site connected with the equipment erected and commissioned. 1.2.2 INSULATION: 1.2.2.1 For GT package, Fuel Gas Line from GVM to GT and APU lines have to be insulated. 1.2.2.2 For STG package, insulation of the integral pipelines has to be carried out as per schedule furnished. 1.2.2.3 For BOP package insulation of heat exchangers. 1.2.2.4 The insulation materials will be supplied by BHEL. 1.2.3 PIPING: Only integral piping of the equipments is included in the scope of this tender. Yard piping is excluded from the scope of this tender PAINTING The scope of work shall include supply and application of final painting for the components of Gas turbine, Generator and Auxiliaries, Steam Turbine, Generator and Auxiliaries and integral piping as per the BHEL / Customer / customers consultant painting specification attached herewith.
1.2.4
1.2.5 WELDING SCHEDULES 1.2.5.1 The number of joints indicated in the welding schedules (site weld data) is approximate only and liable for variation, as per site conditions and also design consideration of manufacturing unit.

1.2.5.2 1.2.5.3 1.2.5.4 The welding process, weld joint and material specification may change to suit site requirement. The list is furnished only for estimation purpose. The contractor is not entitled for any additional payment even if there is any increase in quantum of welding. The contractor shall weld the joints of site routing piping as per site requirement, no extra payment shall be made for such additional joints.
Note:
FOR FURTHER DETAILED SCOPE OF WORKS REFER RELEVANT CHAPTERS IN THIS BOOK

VOLUME- I A PART I CHAPTER III
FACILITIES IN THE SCOPE OF CONTRACTOR / BHEL (SCOPE MATRIX) Scope to be Description taken care by PART I BHEL Bidder ESTABLISHMENT FOR CONSTRUCTION PURPOSE: A Open space for office B Open space for storage C Construction of bidders office, canteen and storage building including supply of materials and other services D Bidders all office equipments, office / store / canteen consumables E Canteen facilities for the bidders staff, supervisors and engineers etc F Fire fighting equipments like buckets, extinguishers etc G Fencing of storage area, office, canteen etc of the bidder 1.3.1.1.2 FOR LIVING PURPOSES OF THE BIDDER A Open space B Living accommodation 1.3.1.2.0 1.3.1.2.1 ELECTRICITY Electricity For construction purposes (to be specified whether chargeable or free) Yes Chargeable basis at the prevailing rate. Yes Yes Yes Yes
Sl.No 1.3.1.1.0 1.3.1.1.1
Remarks
Chargeable basis at the prevailing rate. Yes
Yes
Yes Yes Yes Yes
1.3.1.2.1.1 Single point source
1.3.1.2.1.2 Further distribution for the work to be done which include supply of materials and execution

Description Sl.No 1.3.1.2.2 PART I Electricity for the office, stores, canteen etc of the bidder which include: Scope to be taken care by BHEL Bidder Yes Yes Yes Remarks
1.3.1.2.2.1 Distribution from single point including supply of materials and service 1.3.1.2.2.2 Supply, installation and connection of material of energy meter including operation and maintenance 1.3.1.2.2.3 Duties and deposits including statutory clearances for the above 1.3.1.2.2.4 Living facilities for office use including charges 1.3.1.2.2.5 Demobilization of the facilities after completion of works 1.3.1.2.3 Electricity for living accommodation of the bidders staff, engineers, supervisors etc on the above lines.(in case BHEL provides this facility, the scope should be given without ambiguity) WATER SUPPLY Yes
Yes Yes Yes Yes
1.3.1.3.0
1.3.1.3.1 For construction purposes: 1.3.1.3.1.1 Making the water available at single point 1.3.1.3.1.2 Further distribution as per the requirement of work including supply of materials and execution 1.3.1.3.2 Water supply for bidders office, stores, canteen etc
Chargeable basis at the prevailing rate. Yes
1.3.1.3.2.1 Making the water available at single point 1.3.1.3.2.2 Further distribution as per the requirement of work including supply of materials and execution
Yes Yes

Description Sl.No 1.3.1.4.0 1.3.1.4.1 PART I LIGHTING For construction work (supply of all the necessary materials) At office storage area At the preassembly area At the construction site /area For construction work (Execution of the lighting work / arrangements) At office storage area At the preassembly area At the construction site /area COMMUNICATION FACILITIES for site operations of the bidder Telephone, Fax, internet, intranet, email etc COMPRESSED AIR SUPPLY Supply of Compressor and all other equipments required for compressor & compressed air system including pipes, valves, storage systems etc Installation of above system and operation & maintenance of the same Supply of the all the consumables for the above system during the contract period Description PART II YES Yes Scope to be taken care by BHEL Bidder Yes Remarks
1.3.1.4.2
Yes
1.3.1.5.0 1.3.1.5.1 1.3.1.6.0 1.3.1.6.1
1.3.1.6.2 1.3.1.6.3
YES YES
Sl.No
Scope to be taken care by BHE Bid L der
Remarks
1.3.2.1.0 1.3.2.1.1
ERECTION FACILITIES Engineering works for construction Providing the erection drawings for all the equipments covered under this scope
Yes

Sl.No Description PART II 1.3.2.1.2 1.3.2.1.3 Drawings for construction methods As-built drawings wherever deviations observed and executed and also based on the decisions taken at site- example routing of small bore pipes Shipping lists etc for reference and planning the activities Preparation of site erection schedules and other input requirements Review of performance and revision of site erection schedules in order to achieve the end dates and other commitments Weekly erection schedules based on Sl No 1.3.2.1.5 Daily erection / work plan based on Sl No 1.3.2.1.7 Scope to be taken care by Remarks BHE Bid L der Yes In consultati on with BHEL Yes Yes ,,
1.3.2.1.4 1.3.2.1.5 1.3.2.1.6 1.3.2.1.7 1.3.2.1.8
Yes
Yes Yes Yes Yes Yes
,, ,,
For daily monitoring meeting at site
1.3.2.1.9 Periodic visit of the senior official of the bidder to site to review the progress so that works are completed as per schedule. It is suggested this review by the senior official of the bidder should be done once in every two months. 1.3.2.1.10 Preparation of preassembly bay 1.3.2.1.11 Laying of racks for gantry crane if provided by BHEL or brought by the contractor/bidder himself
Yes
Yes Not applicable

1.3.3 LAND FOR SITE OFFICE 1.3.3.1 To establish a temporary site office, fabrication yard and storage area at the job site. The license fee payable shall be Rs. 20 per hundred square meters or part thereof, per month or part thereof, for any land made available to the CONTRACTOR within the provisions hereof and BHEL shall be entitled (without prejudice to any other mode of recovery), to recover license fee from the Running Account Bills / Final bill(s) of the CONTRACTOR and / or any other payments due to the CONTRACTOR from time to time under this or any other contract. 1.3.3.2 BHEL shall not provide to the contractor any residential accommodation to any of his staff and the contractor has to make his own arrangements. 1.3.3.3 Contractor has to furnish along with their offer, the details of requirements of area of space for his office, stores, storage shed. 1.3.3.4 Location and area requirement for office/storage sheds/ fabrication yard shall be discussed and mutually agreed to. 1.3.4 CONSTRUCTION WATER 1.3.4.1 Water shall be provided by BHEL on chargeable basis at one point. However bidder shall arrange for further distribution at their cost. 1.3.4.2 The cost of water supply shall be recovered from the Contractors Running Account Bills at 0.25% of Running Account Bills/ Final bill value. 1.3.4.3 No separate payment shall be made for any contingency arrangement made by contractor, due to delay / failure of water supply. 1.3.5 CONSTRUCTION POWER 1.3.5.1 The construction power will be provided on chargeable basis at the applicable rate of IOCL at a single point and the further distribution is to be arranged by the bidder at his cost. Construction power shall be provided from the nearest Substation / tapping point on chargeable basis 1.3.5.2 The cost of power supply shall be recovered from contractors running account bill as per the table given hereunder on Lumpsum basis based on the category of Load demand depending on their connected load. The connected load in different categories as per each contractor load demand will be provided at 415 Volts through the following 4 assigned feeder categories in the compact sub-stations.

Cat. No. 1 2 3 5 Load Demand Upto 32 A 32A upto 63A 63A upto 125 A 125 A upto 250 A Feeder Rating in CSS (Amps) 32 63 125 250 Cost/ month (Rs) 25,000.00 50,000.00 1,00,000.00 2,00,000.00
1.3.5.3 The required energy meter for measuring power consumption will be provided and installed by BHEL. Any dispute regarding consumption, the BHEL engineer decision is final. 1.3.5.4 EOT crane without operating personnel shall be made available to the bidder, free of charge for erection purposes. The Electric power consumption for the EOT Crane will be charged as mentioned in clause 1.3.5.2. 1.3.5.5 Contractor shall make his own arrangement for alternative source of power supply through deployment of adequate number of DG sets at their cost during the power breakdown / failure. No separate payment shall be made for this contingency. 1.3.5.6 Any duty, deposit involved in getting the Electricity shall be borne by the bidder. As regards contractors office shed also all such expenditure shall be borne by the contractor. 1.3.5.7 Provision of distribution of electrical power from the given single central common point to the required places with proper distribution boards, approved cables and cable laying including supply of all materials like cables, switch boards, pipes etc., observing the safety rules laid down by electrical authority of the State / BHEL / their customer with appropriate statutory requirements shall be the responsibility of the tenderer / contractor. 1.3.5.8 BHEL is not responsible for any loss or damage to the contractors equipment as a result of variations in voltage / frequency or interruptions in power supply.
VOLUME- I A PART I CHAPTER IV

T&PS and MMEs TO BE DEPLOYED BY CONTRACTOR
A: List of minimum major Tools & Plants to be deployed by the contractor S Description no 1 Pick & Carry crane 2 Mobile crane 3 4 5 Trailer with prime mover Hydraulic testing Pump (Manually operated) Strand jack arrangement for erection of Steam turbine & its Generator Capacity 8T 18 T or above 30/40 T Adequate capacity Minimum quantity 01 01 01 01 As required rema rks
NOTE: 1. The required civil works for erection of Steam turbine and steam turbine generator stators by strand jack method will be done by BHEL. If required, the bidder shall carryout strengthening of existing steel structure with their own labour, consumables, T&Ps etc. The required steel / scrap material as available at project site will be issued by BHEL at free of cost. 2. The stores for other than heavy items are located elsewhere (about 3 km away from Erection Site) inside the Refinery compound. 3. For loading and transportation, all necessary T&P such as Trailers, Cranes, Winches, welding generators, slings, jacks, sleepers, rails etc., are to be arranged by the contractor. All the tools & plants required for this scope of work, except the tools & plants provided by BHEL are to be arranged by the contractor within the quoted rates. 4. As there are bound to be interruptions in regular power supply, power cut / load shedding in any construction site due to inherent power shortage in the state. It shall be the responsibility of the contractor to have minimum numbers of diesel operated welding generator sets to get urgent and important work to go on without interruptions. The consumables required to operate the generators are to be provided by the bidders at their cost. 5. Depending upon the nature of work and availability of facilities locally, contractor may have to arrange for a temporary workshop for facilitating uninterrupted progress of work

6. Lubricants and Experienced Crane operator for EOT crane to be arranged by the bidder at their cost. 7. All heavy items such as GT, Generator etc., unloaded at stores nearby to foundation have to be transported to erection site. For loading and transportation, all necessary T&P such as Trailors, Cranes, Winches, welding generators, slings, jacks, sleepers, rails etc., are to be arranged by the contractor. 8. The availability of crane is likely to be hampered from time to time due to routine preventive maintenance or breakdown maintenance. Contractor has to make alternative arrangement or plan / modify / alter his activities to suit the above conditions and the contractor will not be liable for any compensation or extension of time due to this non availability, for maintaining the erection schedule.

T&Ps AND MMEs TO BE DEPLOYED BY BHEL ON SHARING BASIS
List of T&Ps to be made available by BHEL to contractor free of hire charges on sharable basis. Sl. No 1 2 3 4 5 6 7 Description Acid Circulation pumps with necessary tanks, pipes, valves, instruments, fittings etc. 75 T or suitable higher capacity crane, as per requirement, at the discretion of BHEL Special tools and tackles supplied by BHEL Manufacturing Units EOT Crane in STG Hall - capacity 25 / 5T EOT Crane in BFP area -capacity 15 T Hydro-Test Pump Qty 1 set 1 No. As required 1 No. 2 Nos. 1 no
VOLUME- I A PART I CHAPTER - V
Temporary piping, Valves/ Pumps/ tanks etc. As required required for any commissioning requirement, at the discretion of BHEL
Note: 1. 2. 3. The contractor has to arrange operator for EOT Crane. BHEL will arrange operator for other cranes in BHEL Scope except for EOT Crane. Providing manpower assistance required for free movement of Trailing cable of EOT Crane is included in the scope of this contract. BHEL crane (75 T or suitable higher capacity crane) will be available to contractor only after the contractor deploys all of the minimum T& Ps mentioned in sl no 1 and 2 of the table in chapter IV. Crane operators deployed by the contractor shall be tested by BHEL before he is allowed to operate the cranes. BHEL may provide either BHEL owned cranes or hired cranes at the discretion of BHEL. In the event of providing BHEL Cranes: i) Fuel has to be arranged by the bidder at his cost. ii) Crane operator will be provided by BHEL
4. 5.

In the event of providing hired cranes: The fuel charges shall be recovered as given below: For 75 T crane: Rs. 120/hr For 150 T/ 135 T/100T crane: Rs 200 /hr For Heavy duty crane: Rs 250 /hr 6. Besides the T & P mentioned above, which is being made available to the contractor on free of hire charges, any additional crane and other T & P which may be required for successful and timely execution of the work covered within the scope of this tender shall be arranged and provided at site by the contractor at his cost. In case if the contractor fails to provide such equipments, BHEL will arrange for the same and the cost will be recovered from the contractors bill with BHEL overheads, as applicable from time to time which may vary even during contract period. All the distribution boards, connecting cables, hoses etc., and temporary connection work including electrical connections for the BHEL issued T & Ps shall have to be arranged by the contractor at his cost. Cranes are only for erection purpose and shall not be available for material handling or transportation purpose. Contractor shall make their own arrangements for material transportation to erection site. The contractor at his cost shall arrange for grouting of anchor points of T & Ps issued to him. Necessary grout materials are to be arranged by the contractor at his cost.
7.
8.
9.
10. For higher capacity crane, the required consolidation and preparation of ground and placing same (including civil work with material) is covered in the scope of contract. The scope includes raising the ground level by the 1 M. 11. Filling pump for hydro Test is to be arranged by the contractor, if required.

VOLUME- I A PART I CHAPTER-VI TIME SCHEDULE
1.6.1 TIME SCHEDULE 1.6.1.1 The entire work of erection testing and commissioning, of Gas Turbines & Generators with associated auxiliaries, Steam Turbines & Generators, including turbine integral piping, as well as BOP Equipment as detailed in the Tender Specification shall be completed as given below from the date of commencement of work at site. a) Block A: The contract period for completion of two GTG (1st & 3rd) and one STG (1st) and part of BOP components is 15 months. The time period for completion of each GTG is about seven months and the phase shift between the first and third GTG is four months. The time period for completion of one STG is about eleven months. The BOP components shall be completed within the contract period. Expected start of work for Block A is Mar 2011 Block B: The contract period for completion of one GTG (2nd) and one STG (2nd) and part of BOP components is 14 months. The time period for completion of the GTG is about seven months and the time period for completion of one STG is about eleven months. The BOP components shall be completed within the contract period. Expected start of work for Block B is June 2011 The start of erection of STG-1st shall be four months from start of GTG-1st The phase shift between first & second GTG shall be of three months and that of the first and second STG shall also be of two months.
b)
c) d)
1.6.1.2 During the total period of contract, the contractor has to carryout the activities in a phased manner as required by BHEL and the program of milestone events. 1.6.1.3 The erection work shall be commenced on the mutually agreed date between the bidder and BHEL engineer and shall be deemed as completed in all respect only when the unit is in operation. The decision of BHEL in this regard shall be final and binding of the contractor. The scope of work under this contract is deemed to be completed only when so certified by the site Engineer. 1.6.2 COMMENCEMENT OF CONTRACT PERIOD The date of commencement of contract period shall be the mutually agreed date between the bidder and BHEL engineer to start the work. In case of discrepancy the decision of BHEL engineer is final.

1.6.3 MOBILISATION FOR ERECTION, TESTING, ASSISTANCE FOR COMMISSIOING ETC., The activities for erection, testing etc shall be started as per directions of Construction manager of BHEL. The contractor has to augment his resources in such a manner that following major milestones of erection & commission are achieved on specified schedules: Milestones Month for Milestones Month first GTG for first STG Erection start Zero month Zero month (Expected start is Mar 2011 for Block-A and June 2011 for Block-B) GT alignment of GT & 2nd month 4th month Generator Byepass stack 4th month 7th month erection completion synchronisation 7th month 10th month 1.6.4 In order to meet above schedule in general, and any other intermediate targets set, to meet customer / project schedule requirements, contractor shall arrange & augment all necessary resources from time to time on the instructions of BHEL. In case any requirement is there to compress the schedule of activities to achieve project completion, then the additional expenses if any incurred will be discussed mutually and settled. BHEL decision in this regard is final and the issue is not arbitrable. CONTRACT PERIOD The contract period for completion of entire work under scope shall be 15 (Fifteen) months for Block A and 14 (Fourteen) months for Block B from the COMMENCEMENT OF CONTRACT PERIOD as specified earlier. GUARANTEE PERIOD FOR EACH UNIT The guarantee period of twelve months shall commence from the date of handing over of the Unit to Customer or six months from the date of first synchronisation of the set, whichever is earlier (Provided all erection, testing, and commissioning works are completed in all respects). Activity
1.6.5
1.6.6
1.6.7
TECHNICAL CONDITIONS OF CONTRACT (TCC) VOLUME- I A PART I CHAPTER-VII TERMS OF PAYMENT

1.7 Terms of payment : 1.7.1 A) Progressive Payment against monthly running bills for the erected items will be made upto 90% of the accepted price for one GTG. The percentage break-up for the said 90% shall be as per Cl no 1.7.1.1 to 1.7.1.5 of the following table. 1.7.1.1 GAS TURBINE (35 %) A B C D E F G H J K L M 1.7.1.2 A B C D E F Foundation preparation and sole plate grouting Placement of bearing pedestals Placement of Gas Turbine Placement of L.G.B and coupling Placement of starting means Placement of accessory modules Reaming, coupling & Alignment of GT, LGB and Generator & Starting means Erection of GT base enclosure Erection of off Lube oil & Fuel module including LO centrifuge GT vent fans & Exhaust frame cooler fans GT CO2 Racks & Sys Miscellaneous works on GT DUCTING (Completion of all erection activities) (22 %) Inlet Filter Unit Inlet Ducting inlet Silencer Exhaust Diffuser with expansion joints Exhaust Duct & By pass Duct/stack Support Structures Dampers with Seal air fans & System completion % 1.0 % 1.0 % 8.0 % 1.0 % 1.0 % 2.0% 4.0% 5.0% 4.0% 2.0% 2.0% 4.0% 6.0 % 2.0% 1.0% 8.0% 1.0% 4.0% 1.0% 4.0% 1.0% 2.0% 2.0% 2.0% Rate sched ule ID GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG
1.7.1.3 GAS TURBINE GENERATOR (12%) A Preparation of Foundation and leveling of Base Plates & packers etc. and grouting B Erection of Generator Stator C Erection of bearings D Rotor insertion (if separate, otherwise add to Generator erection) E Erection of exciter, coupling and alignment F Air coolers duct

1.7.1.4 GAS COMPRESSOR & AUX (16%) A Compressor, Gear box assly on Base frame with oil and gas piping around m/c B Compressor drive motors C Lub oil console and lub oil overhead tank D All Coolers 1.7.1.5 A B C D E 1.7.1 COMMISSIONING of GTG ( 5%) Oil flushing completion (GTG) Cranking of GT Full Speed No Load Synchronisation Trial operation completion 10.0% GTG 2.0% 2.0% 2.0% 1% 1% 1% 1% 1% GTG GTG GTG GTG GTG GTG GTG GTG
B) Progressive Payment against monthly running bills for the erected items will be made upto 90% of the accepted price for one STG. The percentage breakup for the said 90% shall be as per Cl no 1.7.1.6 to 1.7.1.9 of the following table. % 2.0% 2.0% 8.0% 2.0% 2.0% 2.0 % 2.0% 2.0% 2.0% 2.0% 2.0% 4.0% 1.0% 5.0% 2.0% Rate sched ule ID STG STG STG STG STG STG STG STG STG STG STG STG STG STG STG
1.7.1.6 STEAM TURBINE AND AUXILIARIES (40%) A B C D E F G H J K L M N O P Foundation Preparation and Matching, laying of packers Placement of pedestals, base plates, leveling & tightening of foundation bolts Placement of turbine with rotor and completion Erection of emergency stop valve and control valves Alignment of turbine rotor with generator Grouting of turbine, generator and exciter with PGM Final alignment, coupling, reaming if required, fixing of coupling bolts & tightening Final box up of bearing end covers etc. after oil flushing and cleaning of bearing pedestals Erection of governing console Erection of Gland Steam Condenser Erection of Steam Jet Air Ejector Turbine integral piping including all drains Application of insulation for integral piping Erection of Deaerators and FST, Alignment, Welding, etc. including platforms Erection of LP Heater, IFO Heater

1.7.1.7 SURFACE CONDENSER (17%) A Placement, Leveling & Alignment of Condenser Assembly B Alignment & welding of Hot Well with Condenser Assembly, Erection of all fittings C Hydro Test of condenser D Welding of condenser with turbine casing 1.7.1.8 STEAM TURBINE GENERATOR AND EXCITER (28%) A Foundation chipping, matching and leveling of base plates and packers B Generator stator placement, centering and leveling C Rotor insertion and completion of alignment D Erection of exciter E Alignment of generator with exciter F Erection of Coolers and other auxiliaries 1.7.1.9 COMMISSIONING OF STG (5%) A Oil Flushing B Steam Blowing C Rolling D Synchronization E Trial Operation STG 10.0% STG 2.0% STG 3.0% 2.0% 2.0% 10.0% 5.0% 4.0% 3.0% 4.0% 1% 1% 1% 1% 1% STG STG STG STG STG STG STG STG STG STG STG STG STG STG STG
FOR BOP SYSTEMS: 1.7.1 C) Progressive Payment against monthly running bills for the erected items will be made upto 90% of the accepted price for the BOP. The percentage breakup for the said 90% shall be as per Cl no 1.7.1.10 (given in following the table) and according to Cl no 1.7.1 D given below. 1.7.1.10 A B C D E F G H J K L Description Fuel system Refinery Gas system for GTG Dosing systems Blow down system Feed water system Make-up water system Condensate system Cooling water system Black start cooling water System Diesel Generator Set Miscellaneous Equipments TOTAL % Percentage Rate schedule ID 12% BOP 10% BOP 3% BOP 15% BOP 25% BOP 3% BOP 3% BOP 7% BOP 2% BOP 2% BOP 8% BOP 90%

Note A: Each of the above percentage of BOP systems may be split up by the BHEL site-Incharge depending on the work content of each of the systems to make progressive payment to the contractor. 1.7.1 1 2 3 D) For BOP Equipment, the above percentages will be further sub divided as per activities indicated below, wherever applicable. Erection of equipments like pumps, motors, skids etc. Alignment of the equipment and ready for trial run Trial run of equipment alone individually 50% 45% 5%
1.7.2 Further 10 % payment on pro-rata basis common to all equipments for the erected items covered under this contract shall be released on achievement of the following stage / milestones events. A B C D E F Application of final painting Area cleaning, temporary structures cutting / removal and return of scrap Punch list points / pending points liquidation Material reconciliation Completion of unit trial run Completion of contractual obligations TOTAL 4% 1% 2% 1% 1% 1% 10%
1.7.3 In case any requirement is there to compress the schedule of activities to achieve project completion, then the additional expenses if any incurred will be discussed mutually and settled. BHEL decision in this regard is final and the issue is not arbitrable. Note B: 1 The Lump sum quoted value in the price bid shall include for the Variation of +15% (Fifteen percent) in quantity for Erection Works In case of variation in weight beyond +15%, the quantity exceeding +15% of the tendered quantity will be paid at the average tonnage rate arrived at as mentioned in the price bid. 2 Recovery of Retention amount as per Cl. 2.22 of GCC. 3 RA bill payments as per Chapter-X of SCC. 4 Payment for the first running bill will be released only on production of the following. i. PF Regn. No. ii. Labour License No. iii. Workmen Insurance Policy No. iv. Unqualified Acceptance for Detailed L.O.I. v. Initial 50% Security Deposit.
TECHNICAL CONDITIONS OF CONTRACT (TCC) VOLUME- I A PART I CHAPTER VIII TAXES AND OTHER DUTIES
1.8.0 TAXES 1.8.1
Value Added Tax (VAT) for the works
1.8.1.1 Price quoted shall be exclusive of VAT (WCT) and service tax. 1.8.1.2 As per the Orissa Gazette Notification dt 13.1.2009, VAT (WCT) is exempted for the execution of Works Contract to IOCL, Paradeep Petroleum Refinery Project. 1.8.1.3 The bidder shall get registered with State VAT authorities and the registration certificate shall be forwarded to BHEL immediately after commencement of work. In case the bidder had already registered under respective State VAT, they must quote their registration Number and forward copy of Registration Certificate while submitting this tender. 1.8.1.4 The bidder shall quote very competitive price after taking into consideration of above points. 1.8.2.0 Service Tax 1.8.2.1. Price quoted shall be exclusive of Service Tax. The service tax as statutorily leviable and payable by the bidder under the provisions of service tax Law / Act shall be paid by BHEL as per bidder claim through various running bills. The bidder shall furnish proof of service tax registration with Central Excise Department specifying the name of services covered under this contract. Registration Certificate should also bear the endorsement for the premises from where the billing shall be done by the bidder on BHEL for this project. The bidder shall obtain prior consent of BHEL before billing the service tax amount. 1.8.3.0 Other Taxes & Levies 1.8.3.1 Any other taxes and duties (except VAT & Service Tax) if any, as applicable, viz. Entry Tax, Octroi, Licenses, Deposits, Royalty, Stamp Duty, other charges / levies, etc. prevailing / applicable on the date of opening of technical bids and any variation thereof during the tenure of the contract are in the scope of bidder. In case BHEL is forced to pay any such taxes, BHEL shall have the right to recover the same from the bidder either from running bills or otherwise as deemed fit. New Levies / Taxes In case Government imposes any new levy / tax after award of the work during the tenure of the contract, BHEL shall reimburse the same at actual on submission of documentary proof of payment subject to the satisfaction of BHEL that such new levy / tax is applicable to this contract..
1.8.4.0 1.8.4.1

1.8.5.0 1.8.5.1 Statutory variations Statutory variations are applicable only in the cases of Value Added Tax and Service Tax. The changes implemented by the Central / State Government in the VAT Act / Service Tax during the tenure of the contract viz. increase / decrease in the rate of taxes, applicability, etc. and its impact on upward revision / downward revision are to be suitably paid/ adjusted from the date of respective variation. The bidder shall give the benefit of downward revision in favour of BHEL. No other variations shall be allowed during the tenure of the contract.
1.8.6.0 Direct Tax 1.8.6.1 BHEL shall not be liable towards Income Tax of whatever nature including variations thereof arising out of this contract as well as tax liability of the bidder and their personnel. Deduction of tax at source at the prevailing rates shall be effected by BHEL before release of payment as a statutory obligation, unless exemption certificate is produced by the bidder. TDS certificate will be issued by BHEL as per the provisions of Income Tax Act.
VOLUME- I A PART I CHAPTER - IX WEIGHT SCHEDULE

1.9.1 WEIGHT SCHEDULE SUMMARY: Sl no Description 1 GTG components (3 nos of Frame 9) 2 STG components( 2 nos of 30MW each) 3 BOP components TOTAL 1.9.2 WEIGHT SCHEDULE FOR BLOCK A & BLOCK B 1.9.2.1 The above total weight to be erected is divided into two blocks as detailed below: (Refer Cl 26.0 of Notice Inviting Tender (NIT) in this booklet for mode of award of work to Block A & B) No 1 2 3 1.9.2.2 No A B C D E F G H J K L Description GTG components STG components BOP components Total Block A Block B Total wt Total in MT Wt in Wt in qty qty (approx) qty MT MT 3 nos 3514 2 nos 2342.6 1 no 1171.3 2 nos 760 1 no 380.0 1 no 380.0 917 458.3 458.7 5191 3180.9 2010.0 Approx. Weight in MT 3514 760 917 5191
The further sub division of above BOP components for the said two blocks is as follows: Description Fuel system Refinery Gas system for GTG Dosing systems Blow down system Feed water system Make-up water system Condensate system Cooling water system Black start cooling water System Diesel Generator Set Miscellaneous Equipment TOTAL WEIGHT Total wt in Wt in MT for Wt in MT for MT (approx) Block A Block B 120 80 40 99 33 66 36 24 12 140 70 70 274 137 137 36 18 18 20 10 10 80 40 40 2 1.3 0.7 50 -50 60 45 15 917 458.3 458.7

1.9.3 WEIGHT DETAILS OF GTG- 3 nos, STG-2 nos & BOP components
Description GTG a) Gas Turbibne Fr-9E Flange to Flange (3 Nos.) b) Accessary Package (accessory Base) (3 Nos.) c) Exhaust Plenum (3 units) d) Diffuser (3 Nos.) f) Field Inter Connection Piping (3 units) g) Enclosure Accessory, GT & Generator Compartment (3 Nos) h) Vent Fans ( 3 units) j) Inlet Duct (3 units) k) Exhaust Duct (3 units) l) Vent Ducting (3 units) m) Piping arrangement Lube Oil Junction boxes (3 units) n) GT inlet air filter house (3 units) o) Unit aux MCC (3 Nos ) p) Other items (3 units) ELECTRICAL MACHINES LIKE GENERATOR, ROTOR TOTAL WEIGHT FOR 3 GTG STG TURBINE GENERATOR STATOR ROTOR, EXCITER HEAT EXCHANGER COMPONENTS TOTAL WEIGHT FOR 2 STG BOP Fuel system Refinery Gas system for GTG Dosing systems Blow down system Feed water system Make-up water system Condensate system Cooling water system Black start cooling water System Diesel Generator Set Miscellaneous Equipment TOTAL WEIGHT BOP Rate Weight in sched tons ule ID 690.000 180.000 35.000 25.000 96.000 300.000 30.000 260.000 375.000 75.000 36.000 390.000 36.000 176.000 810.000 3514.000 GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG GTG
168.100 STG 157.700 STG 434.360 STG 760.000 120.000 99.000 36.000 140.000 274.000 36.000 20.000 80.000 2.000 50.000 60.000 917.000 BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP

1.9.4 WEIGHT SCHEDULE DETAILED SHIPPING WEIGHTS AND DIMENSION A PROJECT : 3 X Fr 9E, IOCL PARADIP Doc No: GTEK/W&D/FR9/IOCLP/10 Weight of Sl Dimensions of box TOTAL Qt shipment N DESCRIPTION (Length x Width x Height) WEIGHT y kg(each o (m) / Volume m3 (Kg) turbine) Gas Turbine Fr-9E 1 1 230,000 13.2 x 4.6 x 5 690,000.00 Flange to Flange Accessory Package 2 1 60,000 8.4 x 3.4 x 4.8 180,000.00 (Accessory Base) Exhaust Frame 3 1 1,000 2.2 x 1.5 x 1.5 (2 Nos.) 3,000.00 Blowers 1 4500 6 x 4 x 5 ( 2 Nos)- TOP 13,500.00 4 Exhaust Plenum 1 6500 6 x 4.5 x 4- LOWER 19,500.00 1 800 2.5 x 1 x 1-Loose items 2,400.00 Base Exhaust 5 1 2000 6.5 x 1.2 x 1 (2 nos) 6,000.00 Plenum 6 Diffuser 1 8500 6.5 x 6.5 x 3 25,500.00 Lube oil centrifuge 7 1 2500 2.5 x 1.5 x 1.8 2,500.00 (see note 1) Load Coupling with 8 1 2850 4.5 x 1.5 x 1.1 8,550.00 Hardware Accessory Coupling 9 1 500 2.2 x 1 x 1 1,500.00 & Hardware Guard Coupling 10 1 300 1.5 x 1 x 1 900.00 Accessory Jacking Oil Skid 11 1 1200 2.2 x 1.5 x 1.5 3,600.00 (EM Engg) Piping Lube Oil 12 1 1200 6.5 x 1.5 x 1.5 3,600.00 Flush Field Field Inter 13 1 32000 6.5 x 1.5 x 1.1 (10 nos) 96,000.00 Connection Piping Enclosure Accessory GT & 14 1 100000 250cu m (In ~22 boxes) 300,000.00 Generator Compartment 1 2.5 x 2.5 x 3.5 (2No.s) 15 Vent Fans 1 10,000 1.8 x 1.8 x 2.0 (2No.s) 30,000.00 1 1.5 x 1.5 x 2.0(1No)
To Rate tal sched Qt ule ID y 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 1 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG 3 GTG

16 Inlet Duct i) Inlet Plenum Extension ii) Inlet duct transition piece iii) Inlet Duct Expansion Pieces iv) Inlet Duct Elbow v) Silencer vi) Duct Pieces vii) Support Structure 17 Exhaust Duct i) Vertical Duct Asse mbly FR9N-VD-1 ii) Vertical Duct Ass embly FR9N-VD-2 iii) Vertical Duct Ass embly FR9O-VD-3 iv) Silencer Assembly FR9N-SLI v) Silencer Assem bly FR9N-SL2 vi) Transition Duct Assembly FR9N-TIL vii) Transition Duct Assembly FR9NTIR viii) Transition Duct Assembly FR9N-T2 ix) Expansion Joints xi) Horizontal Duct HIU HIL H2 HO U HOL xii) Silencer panels 18 Gas Valve Module CO2 Cylinders GTG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1,500 4.5 x 2.3 x 3.0 (2 nos) 9500 9.8x2.3x1.7 1,900 10 x 3.7 x 0.4 ( 2 nos.) 11,100 10 x 3.7 x 3.8 20,200 10 x 3.7 x 3.1 6900 10 x 2.3 x 3.1 (2 nos) 35,000 10x2.5x2.5- 4nos 6,455 6.72 x 3.435 x 3 (2 nos) 6,455 6.72 x 3.435 x 3 (1 no.) 7,648 6.72 x 3.435 x 3.508 (1 no.) 4,500.00 3 GTG 28,500.00 3 GTG 5,700.00 3 GTG 33,300.00 3 GTG 60,600.00 3 GTG 20,700.00 3 GTG 105,000.00 3 GTG GTG 19,365.00 3 GTG 19,365.00 3 GTG 22,944.00 3 GTG 33,795.00 3 GTG 33,714.00 3 GTG 13,638.00 3 GTG 13,476.00 3 GTG
11,265 6.9 x 3.4 x 3.050 (2 nos) 11,238 6.9 x 3.4 x 3.050 (2 nos) 4,546 3.42 x 6.87 x 2 (1 no) 4,492 3.42 x 6.87 x 2 (1 no)
9,058 6.63 x 3.31 x 3.52 (2 nos) 27,174.00 3 GTG 2,000 6 x 4 x 0.4 (3 nos) 9,335 9,664 7,040 5,664 6,062 25,000 7000 6.5X3.3X4.0 I no 6.7X3.3X4.0 -lno. 6.7X3.5X2.8 (2 no) 4.2X2.8X2.8 (1 no) 4.2X3.4X2.8 (I no) 3. 1x6.1 xO.5 (16 nos) 3.6x2.4x 4 3.5 x 1 x 2.5 (4 RACKS 4,000 nos.) 12000 0.5x0.5x2.0- (79 nos) 6,000.00 3 GTG GTG 28,005.00 3 GTG 28,992.00 3 GTG 21,120.00 3 GTG 16,992.00 3 GTG 18,186.00 3 GTG 75,000.00 3 GTG 21,000.00 3 GTG 12,000.00 3 GTG 36,000.00 3 GTG
19 C02 Rack - Frames 1

20 Lube Oil Demister 21 Vent ducting Portable lube oil 22 drain pump (see note 1) Compressor Water 23 Wash Skid (see note 1) Piping Arrangement 24 Lube oil Junction Boxes Piping Arrangement 25 Lube oil Junction Boxes Anchoring, Base Plates Positioning 26 Blocks (Foundation Hardware-Concrete Embedments) Anchoring, Base Plates Positioning 27 Blocks (Foundation Hardware Shims, Guide block etc) Anchoring, Base Plates Positioning 28 Blocks (Angle 75x75x45000) 29 30 31 32 33 34 35 GT inlet air Filter house GT Auxiliary panel Haz gas monitor Radiation shield assy. Boroscope (see note 1) Special Tools for GT Maintenance (Tools) (see note 1) Special tools for GT maintenance(Tools chest) (see note 1) 1 1 1 1 1 1 1 3,000 2.5 x 1,6 x 2.5 (1 no) 25000 1.6x1.2x6 8 boxes 2000 1.6 x1.4x1.2- 1 no 7000 8x3.5 x 3.2 2000 6.0 x 1.5 x 1.1 (4 nos) 12000 6.5x 1.2x I (3No.s) 6.0x l.5x 1.1 (2No.s) 9,000.00 3 GTG 75,000.00 3 GTG 2,000.00 1 GTG 7,000.00 1 GTG 6,000.00 3 GTG 36,000.00 3 GTG 3 GTG
3350 1.2 x 1.5 x 3.5
10,050.00 3 GTG
1900 0.5 x 0.5 x 1.5
5,700.00 3 GTG
1 1 1 1 1 1 1 1 1
425
6 x 0.175 x 0.325 (7 nos) 3 x 0.175 x 0.325 (1 no)
1,275.00 3 GTG 1,275.00 3 GTG 390,000.00 3 GTG 900.00 3 GTG 150.00 3 GTG 600.00 3 GTG 225.00 1 GTG 550.00 1 GTG 500.00 1 GTG
130000 10 X 3.5 X 3.5 (16Boxs) 300 1 X 1 X 2.5 50 0.2 X 0.4 X 0.2 200 0.8 x 0.8 x 0.6 225 1 x 1 x 1 550 1 x 1 x 2.2 500 1 x 1x 1

36 Special tools for GT maintenance (Hyd. Torque wrench) (see note 1) Special tools for GT maintenance (Tool kit major disassy) (see note 1) Special tools for GT maintenance(Lifting beam) (see note 1) Rotor stand Vibration monitoring system MHAMS hard ware & software Unit Aux MCC 125V DCDB SUBTOTAL 1 350 0.8 x 1 x 1 350.00 1 GTG
37
820 1 x 1 x 2.2
820.00 1 GTG
38 39 40 41 42 43
1 1 1 1 1 1
4000 10 x 1.5 x 1 2200 1.2 x 1.5 x 2.0 (2 nos) 50 1 x 1 x 1 100 1.5 x 1.5 x 1 (2 nos) 12000 13 x 1.4 x 2.5 6000 8 x 1 x 2.5
4,000.00 1 GTG 6,600.00 3 GTG 150.00 3 GTG 300.00 3 GTG 36,000.00 3 GTG 18,000.00 3 GTG 2,704,061. GTG 00
NOTE: 1. These item are common for all GTs (i.e Only 1 No. of each of these is being supplied for the whole project) WEIGHT & DIMENSION SCHEDULE (STEAM TURBINE & AUXILIARIES) PROJECT:IOCL- PARADIP REFINERY 350 MW CPP 2X30 STG TURBINE TYPE :EHNK 50/56-3 S.N.NO. GA004 M/C.Nos :T-0950, T-0951 Total Dimensions of box TOTAL Sl Weigh (Length x Width x WEIGHT no DESCRIPTION Qty t(Kg) Height) (mm) (Kg) 1 Turbine Assembly 1 58000 5800x5200x4800 116,000.00 Lube Oil pump 2 assembly 2 1600 2200x900x1050 3,200.00 Emergency lube oil 3 pump assembly 1 1200 2100x1600x650 2,400.00 Jacking Oil pump 4 assembly 1 400 1800x1800x1500 800.00 Lube Oil 1 5 accumulator set 500 1500x500x1765 1,000.00 B
Tot Rate al schedule Qty ID 2 STG STG 4 STG 2 STG 2 2 STG set

6 Lube Oil Purifier 7 Main Lube Oil Tank 8 Duolex Filter Overhead Lube Oil 9 Tank 10 Governing Console 11 Gear Box 12 Coupling SUBTOTAL C 1 1 1 1400 2000x2000x1800 6000 4550x2700x4000 950 2500x750x2000 2,800.00 12,000.00 1,900.00 6,000.00 1,000.00 20,000.00 1,000.00 168,100.00 2 2 2 2 2 2 2 STG STG STG STG STG STG STG
1 3000 3500x3500x3300 1 500 1600x1600x1400 1 10000 2200x2100x2000 1 500 1000x600x600
WEIGHTS & DIMENSION SCHEDULE ELECTRICAL MACHINES ENGINEERING PRODUCT: 3 X FR-IX, G.T.G TYPE: TARI 1080-36P WORK ORDER-1029430600 Q Total Dimensions of box TOTAL Tot Rate Sl DESCRIPTION t Weight (Length x Width x WEIGHT al schedul no y (Kgs) Height) (mm) (Kgs) Qty e ID 1 Generator package 1 210000 9000X4100X4700 630,000.00 3 GTG FOUNDATION 2 ITMES(Loose Items) 1 8000 24,000.00 3 GTG GENERATOR 3 ENCLOSURE 1 8000 12600X5600X5100 24,000.00 3 GTG 4 EXCITER 1 7000 4600X2020X1803 21,000.00 3 GTG MAINTENANCE 5 WEIGHT (ROTOR) 1 37000 9000X1200X1200 111,000.00 3 GTG SUBTOTAL 810,000.00 WEIGHTS & DIMENSION SCHEDULE ELECTRICAL MACHINES ENGINEERING PRODUCT 30 MW STG TYPE: TARI 800-20P PROJECT: 2X30MW STG, IOCL, PARADIP Sl Total Dimensions of box TOTAL Qt N DESCRIPTION Weight (Length x Width x WEIGHT y o (Kgs) Height) (mm) (Kg) 1 GENERATOR STATOR 1 52000 4500X3500X3300 104,000.00 2 GENERATOR ROTOR 1 12000 6600X1000X1000 24,000.00 FOUNDATION ITEMS 3 (Loose Items) 1 5650 11,300.00 4 BEARINGS 1 3200 1900X550X1250 6,400.00 5 EXCITER 1 5000 3000X2000X2000 10,000.00 6 AVR 1 1000 1000X1000X2300 2,000.00 SUBTOTAL 157,700.00 D
Tot al Qty 2 2 2 2 2 2
Rate sched ule ID STG STG STG STG STG STG

E S n DESCRIPTION o Surface Condenser 1 (Per 30MW STG) Shell Assly (with shell, tube sheet, a support plates, spacers etc) b Hot Well Assly Tubes Misc (Stand pipes, d surge pipes etc) 2 a Steam Jet Air ejector (Per 30MW STG) 2 nos 1 nos 6100 x 1000 x 3600 1500 300 NA 7,200.00 600.00 4 STG 2 c HEAT EXCHANGERS ENGINEERING PROJECT:IOCL PARADIP CPP Dry Dimensions of box TOTAL Qty Weight (Length x Width x WEIGHT (Kg) Height) (mm) (Kg)
Rate Total sched Qty ule ID STG
1 35000 7100X4000X4300 1 3000 2000X2400X1900 7200 OD 19.05 x nos 25020 16BWG x L 4500 1 2000 NA
70,000.00 6,000.00
2 STG 2 STG
50040.00 14400 STG 4,000.00 2 STG
ASSEMBLY Misc ( Starting b ejector)
Gland Steam Conde 3 nser Assly (For STG) (Per 30MW STG) Gland steam 1 a Condenser nos 1 b GSC Ejector assly nos 4 a 5 a ST oil Cooler (Per 30MW STG) Per Cooler STG Air Cooler (Per 30MW STG) Per Element 7 nos 2 nos
1400 500 x L 2300 300 2700 x1200 x1200
2,800.00 600.00
2 STG 2 STG
3700 610 x L 4600
7,400.00
4 STG
960 4300 x 700 x 450
1,920.00
14 STG

Spray cum Tray 6 Deaerator (Total 2 nos required) a b c c e f g Header Feed Storage Tank (Sec-I) Feed Storage Tank (Sec-II) Feed Storage Tank (Sec-III) Feed Storage Tank (Sec-IV) Feed Storage Tank (Sec-V) Loose items (for Stand pipes, Platform etc) 1 set SUBTOTAL 1 nos 1 nos 1 nos 1 nos 1 nos 1 nos 20200 23200 22500 26150 22000 22850 5000 L 9.4 x W 3650 x H 3650 L 11.3 x W 4350 x H 4600 L 10.5 x W 4350 x H 4600 L 12.5 x W 4350 x H 4600 L 10.5 x W 4350 x H 4600 L 11.3 x W 4350 x H 4600 40,400.00 46,400.00 45,000.00 52,300.00 44,000.00 45,700.00 10,000.00 434,360.00 2 STG 2 STG 2 STG 2 STG 2 STG 2 STG 2 set STG
CONNECTED BOP PACKAGES. The approximate detailed weights of ONLY some of the BOP components are listed in the following table. The approx weight of the balance BOP components may be referred from clause no 1.9.3 given above. HEAT EXCHANGERS ENGINEERING PROJECT:IOCL PARADIP CPP Sl Dry Dimensions of box TOTAL Rate Total N DESCRIPTION Qty Weight (Length x Width x WEIGHT sched Qty o (Kg) Height) (mm) (Kg) ule ID Water to Water 1 Heat Exchanger A Per Cooler 2 HP Heater A Per Cooler 3 HPH Flash tank A Per tank SUBTOTAL 1 nos 1 nos 1 nos L 5400 x W 700 x 4000 H 1100 18000 Dia 1400 x L 7100 6600 Dia 2000 x H 4000 12,000.00 18,000.00 6,600.00 36,600.00 3 1 1 BOP
BOP BOP

(a) Sl No 1 2 3 4 5 *6 b SL N O 1 2 3 4 5 *6 SIZE AND WEIGHT SCHEDULE OF MAJOR COMPONENTS OF BFP & BP HRSG Boiler Feed Pump & HRSG Booster Pump UNIT Dimension of box Total Q DESCRIPTION WEIGH (Length x Width x Weight ty T(Kg) Height) (mm) (Kg) BFP Skid (Pump 2250 x 1000 Assly. + Base Plate + 1 5770 23,080.00 x1050 tubing + Seal Coolers) BP Skid (Pump Assly. 1650 x 1200 x 1 2550 10,200.00 + Base Plate + tubing) 950 1150 x 1000 x Gear Box (DD). 1 1200 4,800.00 860 Suction Strainer at BP 1 800 900 x 800 x 1400 3,200.00 Suction (DD) BFP Recirculation 1800 x 550 x 1 350 1,400.00 valve (DD) 1400 Loose Items 3000 NA 3,000.00 SUBTOTAL 45,680.00 NOTE: * This is inclusive of Tools and Tackles (600 kg). UB MD BFP& UB MD Booster Pump UNIT Dimension of box Total Q DESCRIPTION WEIGH (Length x Width x Weight ty T(Kg) Height) (mm) (Kg) BFP Skid (Pump 2250 x 1000 Assly. + Base Plate + 1 5770 23,080.00 x1050 tubing + Seal Coolers) BP Skid (Pump Assly. 1650 x 1200 x 1 2550 10,200.00 + Base Plate + tubing) 950 1150 x 1000 x Gear Box (DD). 2 1200 2,400.00 860 Suction Strainer at BP 1 800 900 x 800 x 1400 3,200.00 Suction (DD) BFP Recirculation 1800 x 550 x 1 350 1,400.00 valve (DD) 1400 Loose Items 3000 NA 3,000.00 SUBTOTAL 43,280.00 NOTE: * This is inclusive of Tools and Tackles (600 kg).
Tot al Qty 4 BOP 4 BOP 4 BOP 4 BOP 4 BOP BOP
Tot al Qty 4 BOP 4 BOP 4 BOP 4 BOP 4 BOP BOP

SIZE AND WEIGHT SCHEDULE OF MAJOR COMPONENTS FOR FUEL SYSTEM SKIDS Weig Dimension of box Total DESCRIPTION Qty ht (Length x Width x Weight (Kg) (Kgs) Height) (m) HSD 25 micron FILTER 3 3000 4X3X3 9,000.00 SKID nos NAPHTHA 25 micron 3 3000 4X3X3 9,000.00 FILTER SKID nos HSD 6 micron FILTER 3 3000 4X3X3 9,000.00 SKID nos NAPHTHA 6 micron 3 3000 4X3X3 9,000.00 FILTER SKID nos HSD 2.0 cubic meter 3 0.9m (Dia)X 5 FALSE START DRAIN 5000 15,000.00 nos m(L) TANK NAPHTHA 2 cubic meter 3 0.9m (Dia)X 5 5000 15,000.00 PURGE DRAIN TANK nos m(L) LUBRICITY ADDITIVE 3 4000 4X3X3 12,000.00 DOSING SKID nos HSD/NAPHTHA 18 1000 0.5(Dia) X 2 m(L) 3,000.00 ACCUMULATORS nos LOOSE ITEMS PIPING NA 25,000.00 SUBTOTAL 106,000.00
Tot al Qty 9 BOP 9 BOP 9 BOP 9 BOP 9 BOP 9 BOP 9 BOP 54 BOP BOP
1 2 3 4 5 6 7 8 9
WEIGHTS & DIMENSION SCHEDULE (BFP DRIVE TURBINE & AUXILIARIES) TURBINE TYPE :HNG32/23-3 S.N.NO. GA006 M/C.Nos :T-0948, T-0949 Total Dimensions of box TOTAL SL Total DESCRIPTION Qty Weight (Length x Width x WEIGHT NO Qty (Kg) Height) (mm) (Kg) Steam Turbine with 1 1 17000 4100x3500x2500 34,000.00 2 BOP base plate 2 Gear Box 1 700 800x100x800 1,400.00 2 BOP 3 Coupling 1 100 900x320x320 200.00 2 BOP 4 Lube oil tank 1 4225 3500x2450x2500 8,450.00 2 BOP 5 Overhead oil tank 1 712 1325x2500 1,424.00 2 BOP Lube oil pump 6 1 4750 3000x3500x800 9,500.00 2 BOP assembly

Duplex filter Oil purification unit Oil accumulator 9 assembly Oil vapour Extraction 10 fan assembly 11 Governing console SUBTOTAL 7 8 1 1 1 2 1 124 625x600x725 1350 1250x1500x1100 250 400x500x1800 100 500x400x500 625 1200x1200x1400 248.00 2,700.00 500.00 200.00 1,250.00 59,872.00 2 BOP 2 BOP 2 BOP 4 BOP 2 BOP
Sl N Equipment /Package Description o 1. PUMPS a. HP Export Feed Water Pumps i) 235 M3/Hr Feed Pumps For HP FW Export To Refinery (Motor driven) ii) LO Skid for HP FW Export Pump iii) 235 M3/Hr Feed Pumps For HP FW Export To Refinery (turbine driven) b. MP Export Feed Water Pumps i) 125 M3/Hr Feed Pumps For MP FW Export To Refinery (Motor driven) ii) LO Skid for MP FW Export Pump iii) 125 M3/Hr Feed Pumps For MP FW Export To Refinery (Turbine driven) 395 M3/Hr MUH Transfer Pumps with c. Motors 74 M3/Hr Condenser Extraction Pumps d. with Motors 600 M3/Hr Condensate Transfer e. Pumps (Motor driven) 600 M3/Hr Condensate Transfer f. Pumps (Turbine driven) 350 M3/Hr Black Start ACW Pumps g. (Motor Driven) Blow Down Transfer Pumps with h. motors i. Dewatering Pumps 2. Dosing Systems HP Dosing System (Tri-Sodium a. Phosphate) for HRSGs
Qty
Dimension (each) L x B x H (M)
Weight (each) Tons BOP BOP
2 2 1 2 2 1 3 4 2 1 1
8M x 2.5M x 2.5M 3M x 1.6M x 1M 8M x 2.5M x 2.5M 5M x 2M x 2M 3M x 1.6M x 1M 5M x 2M x 2M 5M x 2M x 1M 0.75M x 0.75M x 5M 4M x 2.5M x 1M 4M x 2.5M x 1M 2M x 1M x 1M
18 2 12 12 2 9 4 2 5 2 2 0.5 0.15 6
BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP
10 0.75M x 0.75M x 5.5M 4 3 0.5M x 0.5M x 0.55M 4M x 2.5M x 3.5M

LP Dosing System (Hydrazine) for Deaerator LP Dosing System (Ammonia) for Dec. aerator LP Dosing System (Ammonia) for d. Condensate Storage Tank b. Electric hoists for material handling in miscellaneous areas 4. Under-slung single girder crane 3. 5. 6 Chain Pulley Blocks for material handling in miscellaneous areas 1 1 1 7 1 5 4M x 2.5M x 3.5M 4M x 2.5M x 3.5M 4M x 2.5M x 3.5M Capacity 3T each Capacity 3T Capacity- 3T - 1 no Capacity- 2T- 2nos Capacity- 5T- 2nos 6 6 6 BOP BOP BOP BOP BOP BOP BOP BOP BOP
Motor for Motor Driven UB BFP & 2 BP 7 Steam Turbine Driven UB BFP 2 Motor for Motor Driven HRSG BFP & 8 4 BP Note: 1)
The product/ equipment list and weight indicated in this chapter is indicative and for estimation purpose only. 2) There is likelihood of addition of any products / equipment integral to GTG / STG, other than those indicated above. The Quoted / Accepted Rates shall be applicable for such products also. Decision of BHEL in this regard will be final and binding on the contractor.
VOLUME- I A PART I CHAPTER -X GENERAL

1.10.1 All the works such as cleaning, leveling, aligning, trial assembly, dismantling of certain components for checking and cleaning, surface preparation, fabrication of sheets, tubes and pipes as per general engineering practice and as per BHEL Engineers instructions at site, cutting, weld depositing, grinding, straightening, chamfering, filing, chipping, drilling, reaming, scrapping, lapping, fitting-up etc., as may be applicable in such erection works and are necessary to complete the work satisfactorily, shall be carried out by the contractor as part of the work with in the quoted rate. Major machining work, which is only to be carried out in workshops, will be arranged by BHEL. 1.10.2 The work shall conform to dimensions and tolerances given in various drawings and quality manuals provided by BHEL. If any portion of work is found to be defective in workmanship not conforming to drawings or other stipulations, the contractor shall dismantle and redo the work duly replacing the defective materials at his cost, failing which the job will be carried out by BHEL by engaging other agencies and recoveries will be effected from contractors bill towards expenditure incurred including BHELs overhead charges. 1.10.3 Contractor shall execute the work as per sequence and procedure prescribed by BHEL at site. The applicable erection manuals which are available with BHEL site office are to be referred for compliance and guidance before taking up the work. Any rework on this failure to comply with will be to account contractor only. BHEL engineer, depending upon the availability of materials, fronts etc, will decide the sequence of erection and methodology. No claims for extra payment from the contractor will be entertained on the grounds of deviation from the method of erection adopted in erection of similar jobs or for any reason whatsoever. 1.10.4 Contractor has to work in close co-ordination with other erection agency at site. BHEL engineer will co-ordinate area clearance. In a project of such magnitude, it is possible that the area clearance may be less/more at a particular given time. Activities and erection program have to be planned in such a way that the milestone are achieved as per schedule/ plans. Contractor shall arrange & augment the resources accordingly. 1.10.5 The contractor is strictly prohibited from using BHELs regular components like angles, channels, beams, plates, pipe/tubes, and handrails etc for any temporary supporting or scaffolding works. Contractor shall arrange himself all such materials. In case of such misuse of BHEL materials, a sum as determined by BHEL engineer will be recovered from the contractors bill. The decision of BHEL engineer is final and binding on the contractor.

1.10.6 The contractor will be responsible for the safe custody and proper accounting of all materials in connection with the work. If the contractor has drawn materials in excess of design requirements, recoveries will be effected for such excess drawls at the rate prescribed by manufacturing units. 1.10.7 No member of the already erected structure/ platform, pipes, grills, platform, other component and auxiliaries should be cut without specific approval of BHEL engineer. 1.10.8 Contractors shall ensure that all their Staff / Employees are exposed to periodical training programme conducted by qualified agencies / personnel on ISO 9001 2000 Standards. 1.10.9 For other agencies, such as piping, cabling, instrumentation, insulation etc., to commence their work from / on the equipments coming under this scope, Contractor has to clear the front, expeditiously and promptly as instructed by BHEL Engineer. Some time it may be required to re-schedule the activities to enable other agencies to commence/continue the work so as to keep the over all project schedule. 1.10.10 The terminal points decided by BHEL are final and binding on the contractor for deciding the scope of work and effecting the payment for the work done up to the terminals. 1.10.11 Fire Barricade protection is to be done for the purpose of fire safety in the erection area (temporary but with steel structures and GI sheets covering for the fire protection for the unit under operation) as required by BHELs customer / Consultant. 1.10.12 For the purpose of planning, contractor shall furnish the estimated requirement of power (month wise) for execution of work in terms of maximum KW demand. 1.10.13 On Completion of work, all the temporary buildings, structures, pipe lines, cable etc. shall be dismantled and leveled and debris shall be removed as per instruction of BHEL by the contractor at his cost. In the event of his failure to do so, the expenditure towards clearance of the same will be recovered from the contractor. The decision of BHEL Engineer in this regard is final. 1.10.14 If applicable, all piping layout drawings received from BHEL / Hydrabad for pipeline erection to be submitted to Boiler Inspector for approval. After approval of the above drawing, Erection of pipe line to be started. 1.10.15 All the necessary certificates and licenses required to carry out this scope of work are to be arranged by the contractor then and there at no extra cost.

1.10.16 UTILITY POINTS 1.10.16.1 Number of utility points (Service / plant air, service / plant water, service / washing steam, inert gas (N2) etc., shall be indicated in the P & I diagram. Contractor to locate the utility points as advised by site engineer and shall route the piping to these points as per site conditions, and shall submit as built layout with B O M to BHEL for approval. 1.10.16.2 The utility points shall be located at convenient point to handle and to be terminated with brass / bronze valve with suitable connection for hose pipe. 1.10.17 PLATFORMS, CROSSOVERS & CANOPIES Platforms, ladders crossovers for sleepers and canopies shall be fabricated by contractor at site as per site engineers advice within the quoted / accepted rate. Platforms shall also be provided at places where it has not been shown in drawings but if felt necessary by site engineer. Canopies shall be provided for all out door pumps and motors. AS BUILT DRAWINGS Contractor shall be supplied with two extra copies of the layout & drawings. Contractor to incorporate in one of the copy with Red ink all the changes / deviations / alterations etc carried out at site due to various reasons, with site engineers endorsement. Marked up drawings shall be submitted to BHEL for approval. SITE INSPECTION The owner/employer or his authorized agents may inspect various stages of work during the currency of the contract awarded to him. The contractor shall make necessary arrangements for such inspection and carry out the rectification pointed out by the owner/employer without any extra cost to the owner / employer. No cost whatsoever such duplication of inspection of work be entertained.
1.10.18
1.10.19
TECHNICAL CONDITIONS OF CONTRACT (TCC) VOLUME- I A PART I CHAPTER -XI FOUNDATIONS AND GROUTING
The scope of the work will comprise of but not limited to the following: 1.11.1 Foundation for the equipments to be erected shall be provided by BHEL/ clients of BHEL. The dimension of the foundation and anchor bolt pits shall be checked by the contractor for their correctness as per drawings. Further, top elevation of foundations shall be checked with respect to bench mark etc. All adjustments of foundations surfaces, enlarging the pockets in foundations etc. as may be required for the erection of equipments plants shall be carried out by the contractor. Cleaning of foundation surfaces, pocket holes and anchor bolt pits etc., dewatering, making them free of oil, grease, sand and other foreign materials by soda wash, water wash, compressed air or any other approved methods etc., form/shuttering work are within the scope this work. It shall be contractors responsibility to check the various equipment foundations for their correctness with respect to level, orientation, dimensions etc., and ascertained dimensions shall be measured and submitted to BHEL for approval before erection. Also minor chipping, dressing of foundations up to 30 mm for obtaining proper face for packer plates/shims, and may be required for the erection of the equipment/plants will have to be carried out by the contractor without extra cost. The surface of foundations shall be dressed to bring the surface of the foundations to the required level and smoothness prior to placement of equipments Foundation pockets are to be cleaned thoroughly before placing the columns / equipments. Verticality of foundation bolts to be checked along with correctness of the threads and freeness of the nuts movement. If required cleaning of the threads to be done with proper dies. The concrete foundation, surfaces shall be properly prepared by chipping, as required to bring the top of such foundation to the required level to provide the necessary roughness for bondage and to ensure enough bearing strength. All laitance and surface film shall be removed and cleaned and the packers placed with suitable mortar prior to erection of the equipment. Packer plates should not only be blue matched with foundation but also inter-packer contact surfaces between the packers and foundation frame etc., shall also be blue matched by Prussian Blue match checks and required percentage contact shall be achieved by chipping and scrapping as per BHEL Engineers instructions.
1.11.2
1.11.3
1.11.4
1.11.5
1.11.6

1.11.7 All the equipment bases and structural steel bases and foundation pockets shall be grouted and finished as per this specification unless otherwise recommended by the equipment manufacturer. The certificates of the grout is to be submitted BHEL. If necessary test cubes are to be made and tested at site to ensure the quality of the grout as per relevant IS standards. In case grouting with Portland cement is approved, necessary cement, sand etc to be arranged by the contractor including the fine aggregates. All the materials required for grouting including special cements like Conbextra GPI,GP2, ACC- Shrinkkomb-N20, Sika Anckor, NSG/ NSG -1, CICO Excem GP, or its equivalent as approved by BHEL and other materials like Portland cement, sand etc., are to be arranged by the contractor at his cost. It shall be the responsibility of the contractor to obtain prior approval of BHEL, regarding suppliers, type of grouting cements before procurement of grouting cements. Certain packer plates and shims over and above the quantity received as part of supplies from manufacturing units of BHEL will have to be cut out from steel plates / sheets at site by the contractor to meet site requirement. However machining of the packers, wherever necessary, will be arranged by BHEL at free of cost. Works such as minor rectification of foundation bolts, reaming of holes, drilling of dowels, matching of bolts and nuts, making new dowel pin etc. are covered in the scope of work. PROCEDURE FOR GROUTING : Contractor has to carryout the grouting as per the work instructions for grouting available at site.
1.11.8
1.11.9
1.11.10
1.11.11
1.11.12
VOLUME- I A PART I CHAPTER -XII MATERIAL HANDLING AND SITE STORAGE

1.12.1 Loading at BHEL/Customer stores and storage yard, transport to site, unloading at site/working area of equipment placement on respective foundation/location, fabrication yard, pre-assembly bay or at working area are in the scope of work. The scope includes taking materials / Equipments from customer stores / storage yard also. Contractors Quoted / Accepted rate shall be inclusive of the same. Required cranes, tractors, trailer or trucks/ slings/ tools and tackles / labour including operators Fuel lubricants etc for loading & unloading of materials will be in the scope of contractor. Note: The Stores is located at a distance of about 03 km from Erection Site. The equipments / materials from the storage yard shall be moved in sequence to the actual site of erection /location at the appropriate time as per the direction of BHEL Engineer so as to avoid damage / loss of such equipment at site. Sometimes it may become necessary for the contractor to handle certain unrequired components in order to take out the required materials. The contractor has to take this contingency also into account. No extra payment is payable for such contingencies. Materials shall be stacked neatly, preserved and stored in the contractors shed / work area in an orderly manner. In case it is necessary to shift and re-stack the materials kept at work area / site to enable other agencies to carry out their work, same shall be done by the contractor at no extra cost. All pipe and tube ends shall be covered with plastic caps or will be closed with wooden plugs as the case may be.
1.12.2
1.12.3
1.12.4
1.12.5
VOLUME- I A PART I CHAPTER- XIII ERECTION

The scope of the work will comprise of but not limited to the following:
1.13.1 Gas / Steam Turbine received either Skid mounted or in loose assemblies with associated auxiliaries. Main part of generator may be supplied in three independent packages such as rotor, stator & Exciter. 1.13.2 Air filter, inlet ducting, exhaust ducting, guillotine damper and diverter damper, by-pass stack will be supplied in individual loose sections. Site job involves complete assembly, welding and erection. 1.13.3 Water wash skid shall involve welding of stainless steel pipe to and from skid. The piping shall be site routed. 1.13.4 Erection of all the piping systems supplied along with equipments, pumps and other auxiliaries covered in this contract is to be erected by the contractor with in the quoted rate. 1.13.5 Before erecting the valves and other mountings, check for the tag for correct rating with valve schedule. Ensure correct flow direction. Ensure easy accessibility for operation and maintenance of valves. 1.13.6 Normally the valves will have prepared edges for welding. But if it becomes necessary the contractor shall prepare new edges or recondition the edges by grinding or chamfering to match the corresponding tubes and pipes. All fittings like T pieces , weld neck flanges, reducers etc., shall be suitably matched with pipes for welding. 1.13.7 The valves will have to be checked, cleaned or overhauled in full or in part before erection, after chemical cleaning and during commissioning. All the valves, after chemical cleaning, have to be checked, cleaned or over hauled in full or part before erection if called for as part of scope. 1.13.8 Normally weld neck valves will have prepared edges for welding. It may be occasionally necessary to prepare new edges, re-prepare the edges to suit site conditions, which shall be done by the contractor at no extra cost. All fittings like elbows, tees, reducers, flanges, inserts etc., shall be matched with pipes for welding which may required re-edge preparation, grinding etc., The valves will have to be checked, lapped or overhauled in full or in parts before erection / after chemical cleaning / during commissioning. Experienced technicians shall be arranged by the contractor at his own cost. 1.13.9 All the dampers, valves, lifting equipments, power cylinders, etc., shall be serviced and lubricated to the satisfaction of BHEL engineer before erecting

the same and also during pre commissioning. The bearings of dampers shall be properly cleaned, serviced and lubricated before commissioning at no extra cost. Even after commissioning in the equipments, if there are problems in the operation they have to be attended by the contractor during the tenure of the contract. 1.13.10 Ducts / expansion pieces are dispatched to site in loose walls / plates and these are to be assembled at site before erection. 1.13.11 In the case of structural members / ducts in certain cases, the raw material will be supplied in random lengths and the contractor will have to make up the length / prepare the edges to suit the matching profiles, weld / bolt connect the joints at no extra cost. 1.13.12 The contractor shall fabricate piping, install lub oil systems and carry out the acid cleaning of fabricated piping. The contractor shall also service the lub oil system, carry out the hydraulic test of oil coolers. etc., 1.13.13 Pipes above 2" diameter have to be cleaned by means of wire brush as per the instruction of BHEL Engineer and subsequently flushed with air before lifting them into position. For pipes below 2" diameter, shall be sponge cleaned with air flushing. After cleaning is over, the end caps shall be put back in tube openings till such time they are welded to other tubes. Required compressors shall be arranged by the contractor at his cost. 1.13.14 All the drain lines should have sufficient slope towards drain. Provide expansion loops in all the vents and drains as the drawings. All the valve packing with asbestos base to be lubricated once in 6 months till handing over. Necessary gland packing will be supplied by BHEL. 1.13.15 Attachment, welding of necessary instrumentation tapping points, thermocouple pads, root valves, condensing vessels, flow nozzles and control valves etc., both for regular measurements and performance testing to be provided on equiments / its auxiliaries or pipelines covered with in scope of this tender, will also be the responsibility of the contractor and the same will be done as per the instructions of BHEL Engineer. The erection and welding of all above items will be contractors responsibility even if, the Items are supplied by an agency other than BHEL if they are integral to the scope envisaged under this package. 1.13.16 All attachment welding including those for insulation and refractory work coming on the pressure parts shall have to be done by the contractor. The hooks are suitable for stud welding machines. Contractors quoted rate shall include all these contingencies. Attachment welding on pressure parts shall be done by qualified and certified welders only.

1.13.17 Fine fittings, oil system and other small bore piping have to be routed according to site conditions and hence shall be done only in position as per the site requirement. Necessary sketch for routing these lines should be got approved from BHEL by the contractor. There is a possibility of slight change in routing the above pipelines when after completion, to suit the site conditions. The contractor should absorb this cost in his quoted rate. 1.13.18 Additional platforms for approaching different equipments as per the site requirement, which may not be indicated in drawings, shall be assembled and erected by contractor within the quoted price. The steel materials required for these works shall be supplied by BHEL free of cost and the contractor will have to install them to suit the requirement. Works of major nature are not covered under this clause. 1.13.19 Work such as minor rectification of foundation bolts, reaming of holes, drilling of dowels, matching of bolts and nuts, making new dowel pin, etc. are covered in the scope of work. 1.13.20 All hangers, supports and anchors (including concreting or welding) shall be installed as per drawing and complete the installation as per instructions of BHEL Engineer. Normally supports are issued in running meters. Any additional supports as called for by BHEL Engineer shall be fabricated by the contractor and provided at no extra cost. However, the raw material required for fabrication of such supports shall be supplied by BHEL free of cost. (Any machining or threading is involved will only be done by BHEL). 1.13.21 Suspension for piping etc., will be supplied in running lengths and shall be cut to suitable sizes and adjusted as required. Hangers components which are being supplied in loose shall be assembled at site and erected as part of the work. 1.13.22 HSFG Bolts are to be tightened by turn of nut method / Torque Wrench, as per the instruction of BHEL Engineer. The bolted joints shall be jointly checked by BHEL / Customer and contractors personnel for the required tightness and retightened wherever necessary. The tightened bolts shall be identified by color paints. Facility for random checking with calibrated Torque Wrench shall also be provided by contractor. 1.13.23 Incase of any class of work for which there is no such specifications as laid down in the contract such us blue matching, welding of stainless steel parts etc., the work shall be carried out in accordance with instructions and requirements of the BHEL engineer at the quoted rates only. 1.13.24 All welded joints should be painted with anti corrosive paint, once radiography and stress relieving works are over.

1.13.25 D.S.L / equivalent system for hoisting equipments are also to be erected and commissioned including load testing by the contractor within the quoted rates. Required manpower including electricians are to be arranged by the contractor for carrying out commissioning of electrical hoist and load testing of the above electrical hoist. Required loads will be provided by BHEL free of cost. 1.13.26 The temporary structures / items welded to permanent members / pipes are to be cut and removed without any damage. Any damage so to be made good by the contractor at his cost. 1.13.27 Before lifting the heavy components, soft materials like gunny bags to be used while lashing the rope to avoid dents, rubbing marks etc. The capacity, number of sheave pulleys, size of the rope, guide pulley locations are to be decided at site with respect to the capacity and positioning of the winch. The end caps provided at shop for various stubs are to be removed during final fit up only. 1.13.28 Prior to erection of any components inspection to be done for any foreign materials / damages and they are to be removed / attended as per BHEL engineer. 1.13.29 Wherever equipments are supplied in pre-fabricated assembled packages, there may be necessity to make minor changes, including strengthening by additional welds. This shall be treated as part of the contractors scope. 1.13.30 All Rotating machineries and equipment shall be cleaned, lubricated, checked for their smooth rotation, if necessary dismantling and refitting before erection. If in the opinion of BHEL Engineer, the equipment is to be checked for clearance, tolerance at any stage of work or during commissioning period, all such works are to be carried out by contractor at his cost. 1.13.31 For skid mounted equipment, the checking and re-alignment required at site is in the scope of wok. 1.13.32 All the shafts of rotating equipment shall have to be properly aligned to those of matching equipment to perfection, accuracy as required and the equipment shall be free from excessive vibration so as to avoid overheating of bearings or other conditions which may tend to shorten the life of the equipment. 1.13.33 All the equipments / material to be taken inside the plant building shall be cleaned thoroughly before taking them inside and erect. The contractor shall clean, wherever necessary and paint inside surfaces of the equipments like coolers, oil tanks, Rubber expansion joints assemble and other components as per instruction of BHEL Engineer during erection at the quoted rate. 1.13.34 All the bearings, Gearboxes etc., of the equipment and electrical motors to be erected are provided with protective greases only. Contractor shall arrange as and when required by the engineer for cleaning the bearing/gear boxes etc., with

kerosene or some other agent if necessary by dismantling some of the parts of the equipment during erection and shall arrange for re-greasing/lubricating them with recommended lubricants and assembling back. Lubricants will however be supplied by BHEL at free of cost. 1.13.35 All the motors / pumps shall be stripped opened, thoroughly serviced with proper care and re-assembled properly before erection by the contractor. During servicing, pre-commissioning & commissioning, if any deficiency is observed the same should be taken up with BHEL Engineer at site and rectified at site without any delay. 1.13.36 The contractor shall also carry out erection, testing, and commissioning of the oil centrifuge with in their quoted rate. 1.13.37 Certain instruments like pressure switches, gauges, air sets, regulators, filters, junction boxes, power cylinders, dial gauges, thermometers, flow meters, valve actuators, flow indicators etc., are received in assembled conditions as integral part of equipments. Contractor shall dismantle such instruments and re-erect whenever required prior to commissioning. Some time this may have to be handed over to store or instrumentation contractor. 1.13.38 Transportation of H2 and CO2 cylinders from the store and filling of the gas for generator stator cooling and protection system etc., as and when required till the unit is commissioned and handed over shall be the responsibility of the contractor. The cylinders are to be weighed before installation. Arrangements of weighing machine to be done by contractor. 1.13.39 All site-fabricated pipes will be issued in running metres as straight. These are to be cut and edge prepared at site to required length to suit layout as given in the erection drawing. All the attachments like lugs, stoppers, cleats etc., will be supplied as loose items and to be cut and welded to the pipes at site as per erection drawing necessary drilling of holes on main pipe for welding stubs shall also be done at site by the contractor. Fittings like bends, tees, elbow, mitre bends, reducers, flanges etc., will be supplied as loose items and the edge preparation if required shall be carried out by the contractor. 1.13.40 Tubes or pipes wherever deemed to be convenient will be sent in running lengths with sufficient bends. Contractor has to cut and edge prepare as per the standards / drawings and as per the instruction of BHEL Engineer. Bends up to NB 65 mm will have to be fabricated at site adopting specified heat treatment procedures, Wherever required at no extra cost. 1.13.41 Certain adjustments in length may be necessary while erecting pipelines and the contractor should remove the extra lengths / add extra lengths to suit the final layout after preparing edges afresh and adopting specified heat treatment procedure, are in the scope of work. For any mismatch while matching the joints

in tubes, the cutting, adjusting, re welding, addition spool pieces should be done by the contractor to match site conditions without any extra payment. 1.13.42 Certain extra lengths of portions / parts of various fabricated ducts / components parts / bellows / piping etc. are provided as erection allowance and they shall have to be cut to suit site conditions and layout or certain length of portions/parts of ducts/components/bellows/piping casing etc., may have to be added to suit conditions and layouts. No extra payment will be admitted for such works. 1.13.43 Minor adjustment like removal of ovalities in pipes and opening or closing of the fabricated bends by process of heat correction or any other method approved by BHEL Engineer to suit the layout, with specified heat treatment procedure with in the quoted rate. 1.13.44 Contractor shall use only bolted clamps for achieving alignment of piping. Wherever "L" shaped stoppers and wedges are to be used for aligning piping and equipments, the same shall be subject to the approval of BHEL Engineer. Contractor shall remove the bridge, stopper etc., and not by hammer. Any burrs left on the equipments/piping, after welding, shall be ground off or any scar or cavity made good by welding and grinding. NDT tests shall be carried out if necessary to detect surface and sub-surface cracks in these ground areas. 1.13.45 Flame cutting of piping and other equipment shall be strictly done as per BHEL Engineers instructions and in his presence only. 1.13.46 Incase of piping connected to equipment, matching of flanges for achieving the parallelism and alignment at equipment end by suitably resorting to heat correction or other method as instructed by BHEL Engineer is within scope of work. 1.13.47 All the oil & gas piping flanges, wherever provided are to be blue matched using surface plates for at least 80% contact area to attain leak proof of joints. 1.13.48 The surface of the pipes to be joined shall be suitably prepared as per instructions of BHEL Engineers. Edge preparation shall be done by chamfering machine, whenever required and all welding surfaces must be cleaned thoroughly. All works due to the mistake of the contractor shall be repaired / redone at contractors cost. Instrumentation drains, stubs which are sent in loose from manufacturing units are to be welded at site as per BHEL Engineers instructions. 1.13.49 Impulse piping wherever required for BHEL equipment is to be fabricated by the contractor including erection and welding of root valves as per the instructions of BHEL Engineer. The required piping and root valves will be supplied by BHEL free of cost.

1.13.50 All the weld joints on equipments and piping shall be ground or filed after completion of welding and before radiography as per instructions of BHEL Engineer so as to achieve smooth surface to avoid of ripples, undulations etc., 1.13.51 All piping items including pipes, valves, flanges, fittings etc. shall be supplied as commercially available. Hence Fit-ups, edge preparation including welding of stubs, shall be included in the contractor's scope. 1.13.52 Wherever elbows of 45 deg or any other angle are required, the same shall be cut from 90 deg. elbow supplied and used. No extra cost shall be paid. 1.13.53 The work on piping systems (air, water, oil, steam, gas etc.,) will include laying, edge preparation, fixing and welding of the elbows / fittings / valves etc., welded on the lines, fixing and adjustment of supports / hangers / shock absorbers and carrying out all other activities/works to complete the erection and also carrying out all pre-commissioning/commissioning operations mentioned in the specification as per BHEL Engineer's instructions and/or as per approved drawings/documents. 1.13.54 Flow nozzles, orifice, spray nozzles etc., shall be mounted/ erected after chemical cleaning/flushing/or steam blowing at site. 1.13.55 Erection of flow switches, steam traps, filters, flow meters, other metering elements, flow orifices, flow indicators, control valves supplied either by BHEL or customer forming part of the system is in the scope of work. This will include collecting from BHEL / Customer stores, transport to site, suitably cutting the erected piping, cleaning, erection, welding, radiography and stress relieving and commissioning. 1.13.56 Contractor shall also weld small length of piping with root valve to the pressure, flow and level tapping points on piping or flow nozzles/orifices/ metering elements fixed on piping as per the instructions of BHEL Engineer. 1.13.57 All drains/ vents/ relief/ escape/ safety valve piping to various tanks/ sewage/ drain canal/ flash box/ flash tank/ condenser/ sump/ atmosphere etc. from the stubs on the piping and equipments erected by the contractor is completely covered in the scope of work. 1.13.58 The contractor has to fabricate stainless steel orifice plate within the quoted rate. No extra payment will be made for fabrication of above orifice plates. The required stainless steel plate will be supplied by BHEL. 1.13.59 Welding of all thermo wells, stubs, hoses, tapping points, root valves, draft, pressure and temperature instrumentation points and all other instrumentation points on piping and auxiliaries and welding of thermocouple pads for permanent system are in the scope of work.

1.13.60 The contractor shall also weld all thermo wells, small length of pipes to all pressure, flow and level tapping points, isolating valves and root valves on all equipment under scope of erection of this contract. Thermo wells tapping point connections incorporated shall be plugged during the pressure testing and steam blow out of piping systems. Upon completion of blow out operation all thermo wells and flow elements with branch pipes be installed and welded. 1.13.61 All instrumentation impulse lines up to root valves shall also be erected and welded by TIG welding only by the contractor within their quoted value. 1.13.62 The contractor shall conduct non destructive tests like radiography ultrasonic test for weld defects etc., ultrasonic test for finding thickness, dye penetrant tests, magnetic particle test etc., on weld joints, castings, valve bodies and other equipments etc., as per BHEL Engineer's instructions. 1.13.63 Plate / Pipe shoes for piping supports shall be fabricated at site by the contractor at no extra cost. Other supports namely Hangers, U-clamps etc., shall be supplied by BHEL duly bent and threaded. Assembly and necessary cutting work etc., shall be carried out at site by contractor within the quoted rate. 1.13.64 Contractor has to fabricate and erect temporary spool pieces wherever required due to non receipt of valves in time and after receipt of valves the spool pieces are to be replaced with regular valves at free of cost. For spool pieces materials will be supplied free of cost by BHEL. 1.13.65 Wherever hanger and support materials of piping are not received from manufacturing unit in time to suit the erection schedule, contractor shall erect the piping system on temporary supports to ensure the progress of work. The required structural steel materials will be issued on free of charges by BHEL, either from scrap/spare materials. The same shall be removed and returned to BHEL store after erection of permanent supports. 1.13.66 Contractors has to carryout fabrication works such as welding of stubs / nipples, attachments etc., preparation of surface for rust preventive coating and application of rust preventive is within the quoted / accepted rate. 1.13.67 Contractor has to arrange required fire retardant covering material at their cost to protect the machined components / assembled parts drawn from BHEL before and after erection. 1.13.68 The contractor shall provide any fixtures, concrete blocks & wooden sleepers, which are required for temporary supporting / preassembly of the components at site.
TECHNICAL CONDITIONS OF CONTRACT (TCC) VOLUME-I A PARTI CHAPTER-XIV PROGRESS OF WORK

1.14.1 Refer forms F -14 to F-18 of volume I D of volume -I book-II. Plan and review will be done as per the formats. 1.14.2 Contractor is required to draw mutually agreed monthly erection programs in consultation with BHEL well in advance. Contractor shall ensure achievement of agreed program and shall also timely arrange additional resources considered necessary at no extra cost to BHEL. 1.14.3 Progress review meetings will be held at site during which actual progress during the week vis-a-vis scheduled program shall be discussed for actions to be taken for achieving targets. Contractor shall also present the program for subsequent week. The contractor shall constantly update / revise his work program to meet the overall requirement. All quality problems shall also be discussed during above review meetings. Necessary preventive and corrective action shall be discussed and decided upon in such review meetings and shall be implemented by the contractor in time bound manner so as to eliminate the cause of nonconformities. 1.14.4 The contractor shall submit daily, weekly and monthly progress reports, manpower reports, materials reports, consumables (gases / electrodes) report, cranes availability report and other reports as per Performa considered necessary by the Engineer as per the format enclosed with this tender document. 1.14.5 The contractor shall submit weekly / fortnightly / monthly statement report regarding consumption of all consumables for cost analysis purposes. 1.14.6 The monthly report ending on 24th of every month shall be submitted as a booklet and shall contain the following details :a) Colour Progress photographs to accompany the report should be submitted. b) Erection progress in terms of tonnage, welding joints, radiography, stress relieving, etc., completed as relevant to the respective work areas against planned. c) Site Organization chart of engineers & supervisors as on 24th of the month with further mobilization plan d) Category- wise man hours engaged during the previous month under the categories of fitters, welders, riggers, khalasis, grinder-men, gas-cutters,

electricians, crane operators and helpers. Data will be spilt up under the work area of Boiler e) Consumables report giving consumption of all types of gases and electrodes during the previous month. f) Availability report of cranes g) Safety implementation report in the format h) Pending material and any other inputs required from BHEL for activities planned during the subsequent month. 1.14.7 The manpower reports shall clearly indicate the manpower deployed, category wise specifying also the activities in which they are engaged. 1.14.8 During the course of erection, if the progress is found unsatisfactory, or if the target dates fixed from time to time for every milestone are to be advanced, or in the opinion of BHEL, if it is found that the skilled workmen like fitters, operators, technicians employed are not sufficient BHEL will induct required additional workmen to improve the progress and recover all charges incurred on this account including all expenses together with BHEL overheads from contractors bills. 1.14.9 The contractor must obtain the signature and permission of the security personnel of the customer for bringing any of their materials inside the sit premises. Without the Entry Gate Pass these materials will not be allowed to be taken outside.
VOLUME- I A
PARTI CHAPTER-XV WELDING
The scope of the work will comprise of but not limited to the following: 1.15.1 Welding of pressure parts, high tensile structural steel, Piping shall be done by certified high pressure welders who posses valid certificate and who are approved by BHEL Engineer. All welders including tack welders, structural and high pressure welder shall be tested and approved by BHEL Engineer before they are actually engaged on work even though they may possess a valid certificate. BHEL reserves the right to reject any welder if the welder's performance is not found to be satisfactory. The contractor shall maintain the records of qualification AND performance of welders. BHEL Engineer will issue all the welders qualified for the work, an identity card. The welder will keep the same with him at work place at all times. He may be stopped from work if he is not found in possession of the same. Engineer may stop any welder from the work if his performance is unsatisfactory for any technical reason or if there is a high percentage of rejection in the joints welded by him. The welders having passed qualification tests does not absolve the contractor of contractual obligation to continuously check the welder's performance. Faulty welds caused by the poor workmanship shall be cut and re-welded at the contractors expense. The Engineer prior to any repair being made shall approve the procedure for the repair of defective welds. After the repair has been carried out, the compliance shall be submitted to the quality engineer. All expenses for testing of contractor's welders including destructive and Nondestructive tests conducted by BHEL at site or at laboratory shall have to be borne by the contractor only. Limited quantity of tube and pipe material required for making test pieces will be supplied by BHEL free of cost. Only BHEL approved electrodes and filler wire will be used. All electrodes shall be baked and dried in the electric electrode-drying oven to the required temperature for the period specified by the Engineer before these are used in erection work. All welders shall have electrodes drying portable oven at the work spot. All welds shall be painted with anticorrosive red oxide paint once radiography and stress reliving works are over.
1.15.2
1.15.3
1.15.4
1.15.5
1.15.6
1.15.7

1.15.8 Pre-heating, radiography and other NDT tests, post heating and stress relieving after welding, are parts of erection work and shall be carried out by the contractor in accordance with the instructions of the Engineer. The contractor shall also be equipped for carrying out other NDT like LPI / MPI / Hardness test etc. as required as per welding schedules / drawings within the finally accepted price / rates. Ultrasonic testing, wherever required, will be arranged by contractor within the quoted rate.
1.15.9
VOLUME-I A PART- I CHAPTER- XVI TESTING AND COMMISSIONING

The scope of the work will comprise of but not limited to the following: 1.16 TESTING , PRE COMMISSIONING & COMMISSIONING AND POST COMMISSIONING
1.16.1 The Contactor shall carry out all the required tests and pre-commissioning and commissioning activities required for their successful and reliable operation. 1.16.2 All required tests (Mechanical and electrical) indicated by BHEL and their clients for successful commissioning are included in the scope of these specifications. These tests / activities may not have been listed in these specifications. Specialized test equipment, if any, shall be provided by BHEL/ its client free of hire charges. However contractor has to take proper care of the equipment issued to him. 1.16.3 All the tests may have to be repeated till all the equipment satisfy the requirement / obligation of BHEL at various stages. The contractor shall do all the repairs for site-welded joints arising out of the failure during testing. 1.16.4 The scope of pre-commissioning activities cover installation of all necessary equipment including temporary piping, supports, valves, blanking, pumps, tanks, with access platforms valves, along with accessories required for hydro test, chemical cleaning, steam blowing or for any other tests. The scope also covers the off site disposal of effluents. 1.16.5 It shall be the responsibility of the contractor to provide various categories of workers in sufficient numbers along with Supervisors during pre commissioning, commissioning and post commissioning of equipment and attending any problem in the equipment erected by the contractor till handing over. The contractor will provide necessary consumables, T&Ps, IMTEs etc., and any other assistance required during this period. Association of BHELs / Client's staff during above period will not absolve contractor from above responsibilities. 1.16.6 It shall be specifically noted that the above employees of the contractor may have to work round the clock along with BHEL Engineers and hence overtime payment by the contractor to his employees may be involved. The contractors finally accepted rates should be inclusive of all these factors also.

1.16.7 In case, any rework is required because of contractor's faulty erection, which is noticed during pre-commissioning and commissioning, the same has to be rectified by the contractor at his cost. If any equipment / part is required to be inspected during pre-commissioning and commissioning, the contractor will dismantle / open up the equipment / part and reassemble / redo the work without any extra claim. 1.16.8 During commissioning, opening / closing of valves, changing of gaskets, Realignment of rotating and other equipment, attending to leakage and adjustments of erected equipment may arise. The finally accepted price /rates shall also include all such work. 1.16.9 The valves will have to be checked, cleaned or overhauled in full or in part before erection, after acid cleaning, steam blowing and during commissioning as may be necessary. 1.16.10 In case any defect is noticed during tests, trial runs and commissioning such as loose components, undue noise or vibration, strain on connected equipment etc., the contractor shall immediately attend to these defects and take necessary corrective measures. If any readjustment and re-alignment are necessary, the contractor at his cost shall do the same as per Engineers instructions including repair, rectification and replacement work. The parts to be replaced shall be provided by BHEL. 1.16.11 The contractor shall carry out cleaning and servicing of valves and valve actuators prior to pre-commissioning tests and / or trial operations of the plant. A system for recording of such servicing operations shall be developed and maintained in a manner acceptable to BHEL Engineer to ensure that no valves and valve actuators are left un-serviced. Wherever necessary as required by BHEL Engineer, the contractor shall arrange to lap / grind valve seats. 1.16.12 Cleaning and servicing of all the filters / strainers, in the system shall be done by the contractor within the accepted price. All oils and greases to be filled in the main equipments as first fill and subsequent topping offs will be furnished by BHEL. 1.16.13 Transportation of oil drums from customers BHELs stores, filling of lubricants and filling of oil for flushing and first filling and subsequent topping up during commissioning and post commissioning is included in the scope of this contract. The contractor shall have to return all the empty drums to the customer / BHEL stores. Similarly transport of chemicals for various pre-commissioning activities / processes mentioned in the above clauses and returning of remaining and / or the empty containers of the chemicals to customer / BHEL stores is the responsibility of the contractor.

1.16.14 Replacing / cleaning of filters of the erected equipments during precommissioning / commissioning stage are within the scope of work. 1.16.15 During the initial stages of work, trenches for draining water may not be available for alkali flushing or mass flushing for discharging and draining the system and piping. Necessary low point drains and temporary piping for this will have to be erected by contractor from materials provided by BHEL. 1.16.16 Contractor may have to replace old/damaged gaskets / packing etc. for equipments and the same shall be carried out by contractor as per requirement. Materials will be given by BHEL. 1.16.17 In case any erection defect is detected during various tests / operations trial runs as detailed above such as loose components undue noises or vibration strain on connected equipment steam or oil or water leakage etc. the contractor shall immediately attend these defects and take necessary corrective measures. The parts to be replaced shall be provided by BHEL free of cost. If the insulation is to be removed to attend any of the defects the cost of removal and reapplication of insulation should be borne by the contractor. 1.16.18 Necessary scaffolding and approaches for conducting the above shall also be within the scope of the contract. 1.16.19 The contractor shall carryout any other test as desired by BHEL Engineer on erected equipment covered under the scope of this contract during testing, precommissioning, commissioning, and operation, to demonstrate the completion of any part or whole work performed by the contractor. 1.16.20 Contractor shall cut / open works if needed, as per BHEL engineers instructions during commissioning for inspection, checking and make good the works after inspection is over. This contingency shall be included within the quoted value. During commissioning opening of valves, changing of gaskets, attending to leakages, minor modification / rectification works may arise. The contractor has to carry out these works at his cost by providing required manpower in all the three shifts. In case any rework is required because of contractors faulty erection and which is noticed during commissioning the same has to be rectified by the contractor at his cost. 1.16.21 Assistance for calibrating / testing the power cylinders / valves, gauges, instruments, etc. and setting to actuators shall be provided by contractor within the quoted rates. 1.16.22 Contractor to provide necessary commissioning assistance from precommissioning state onwards and up to continuous operation of the unit & handing over to customer. The category of personnel to be as per site requirement and to meet the various pre-commissioning and commissioning programmes made to achieve the schedule agreed with customer.

1.16.23 After synchronization, the commissioning activities will continue. It shall be the responsibility of the contractor to provide manpower including necessary consumables, hand tools and supervision as part commissioning assistance. 1.16.24 It shall be specifically noted that the contractor and employees of the contractor may have to work round the clock during the pre-commissioning, commissioning and post-commissioning period along with BHEL Engineers / customer officials. Hence contractors quoted rate shall take into consideration of all expenses that will be incurred for such arrangement of personnel including engineers / supervisors. 1.16.25 The valves, dampers, actuators etc. will have to be checked cleaned and overhauled in full or in part before erection, after acid cleaning, steam blowing and during commissioning as maybe necessary. 1.16.26 During commissioning any improvement / repair / rework / rectification / fabrication / modification due to design improvement / requirement is involved, the same shall be carried out by the contractor promptly and expeditiously. 1.16.27 Contractor at his cost shall lay all necessary temporary piping, install the pumps, blanks ,valves pressure gauges etc required for the test,. Contractor shall also lay the temporary pipelines with fittings, accessories and erection / commission pumps, tanks and other installations as instructed by BHEL Engineer for the purpose of chemical cleaning / alkali flushing / steam blowing / steam washing / steam flushing/water flushing / water washing/oil flushing etc., of piping and other equipments. Necessary, materials for this will be provided by BHEL. Temporary piping, fittings, accessories, pumps, valves, flanges, blanks etc shall be removed by him and returned to BHEL. 1.16.28 Chemical cleaning (Acid cleaning of piping / alkali flushing) will involve the installation of temporary piping, valves, cutting of some of the existing valves, placing the rubber for chemical and for mixing. Necessary temporary access platforms to mixing tank are to be made by the contractor. The dissolving tank, neutralizing tank etc. required for acid pickling will have to be fabricated by the contractor. Required materials will be provided by BHEL free of cost. 1.16.29 Overhauling / cleaning / servicing of valves, pumps, fittings in temporary system and acid cleaning tanks etc prior to the above operations / activities will also be carried by the contractor at his cost. 1.16.30 Replacing / changing mechanical / other seals, removal and cleaning / replacing of filters etc. during pre-commissioning / commissioning stage is within the scope of work. 1.16.31 Contractor shall lay all necessary electric cables and switches etc. required for the hydraulic tests and other tests, flushing etc., and maintain the system till the tests are completed satisfactorily.

1.16.32 After the chemical cleaning has been successfully completed, removing all temporary piping, fittings of tanks etc., Checking all the valves for any accumulation of foreign materials, welding the valves, pipes which were cut and cleaning, re-fixing as per BHEL Engineers instructions is within the scope of work/ specification. 1.16.33 All the tests shall be repeated till all the equipment satisfy the requirement of BHEL / Customer. As far as the hydraulic pressure test is concerned and same shall be conducted to the satisfaction of Boiler Inspector wherever applicable. Any rectifications required shall have to be done / redone by the contractor at his cost. 1.16.34 Transportation of oil drums from customer's / BHEL's stores. Filling of lubricants and filling of oil for flushing and first filling and subsequent topping up during commissioning and post commissioning is included in the scope of this contract. The contractor shall have to return all the empty drums to the customer/BHEL stores. Similarly transport of chemicals for various pre-commissioning, commissioning activities and related processes and returning of remaining and/or the empty containers of the chemicals to customer/BHEL stores is the responsibility of the contractor. 1.16.35 Overhauling, cleaning, Servicing of tanks, pumps, equipments, barring gear, valves, governing system during erection and commissioning stages are in the scope of work. Gaskets packing required for replacement will be provided by BHEL free of cost. 1.16.36 Cleaning of oil tank as per the instructions of BHEL Engineer before and after oil flushing is responsibility of the contractor. 1.16.37 Pre commissioning of oil lines includes oil flushing of the pipelines till the entire system and the pipelines are accepted as satisfactorily cleaned after inspection of sediments in the centrifuge bowl and laboratory tests of the oil samples taken from the system. After declaration of complete oil flushing of system including oil tank and coolers shall be completely drained thoroughly cleaned and refilled with fresh oil for putting the set on operation. Before commissioning of oil system the pipelines should be hydraulically tested using the hydraulic test pump to the required pressure. 1.16.38 All shaft journals and bearings shall be periodically inspected and preservation shall be done as per BHEL Engineer's instructions. 1.16.39 The contractor shall carryout the required tests on the equipments and the pipelines such as gas tightness test/air tightness test, kerosene test, hydrostatic testing of the equipment/piping etc., and rectify all the defects caused due to contractor's fault at his own cost. Contractor may have to replace old/ damaged gaskets / packing etc. for equipments and the same shall be carried out by

contractor as per requirement. Compressed air for pneumatic testing is to be arranged by contractor. The contractor shall carry out the trial run of motors including checking the direction of rotation in the uncoupled condition checking aligning and coupling the motor to the respective driven equipment. Before starting the motor, IR values of insulation shall be recorded and if found necessary the contractor shall dry out to improve the IR value at no extra cost. 1.16.40 In case any erection defect is detected during various tests / operations trial runs as detailed above such as loose components undue noises or vibration strain on connected equipment steam or oil or water leakage etc. the contractor shall immediately attend these defects and take necessary corrective measures. If any readjustment and realignments are necessary the same shall be done as per BHEL Engineer's instructions. If any part needs repairs rectification and replacement the same shall be done by the contractor at no extra cost. The parts to be replaced shall be provided by BHEL free of cost If insulation is to be removed to attend any of the defects the cost of removal and reapplication of insulation should be borne by the contractor. 1.16.41 Necessary scaffolding and approaches for conducting the above shall also be within the scope of the contract. 1.16.42 The contractor shall carryout kerosene test of all the bearing housing of turbine and generator, bearing housing of pumps and other equipments and do the repair work if any. The contractor at his cost shall also arrange kerosene. 1.16.43 The contractor shall carryout any other test as desired by BHEL Engineer on erected equipment covered under the scope of this contract during testing, precommissioning, commissioning, and operation, to demonstrate the completion of any part or whole work performed by the contractor. 1.16.44 During the stages of pre-commissioning / commissioning / post commissioning, if any part of the GTG / STG and auxiliaries need, repair/rectification / rework / replacement, the same shall be done expeditiously and promptly by the contractor. 1.16.45 Contractor shall cut/open works if needed, as per BHEL Engineer's instructions during commissioning for inspection, checking and make good the works after inspection is over. This contingency shall be included within the quoted value. During commissioning, opening of valves, changing of gaskets, attending to leakages, minor modification rectification works etc., may arise. The contractor has to carry out these works at his cost by providing required manpower in all the three shifts. In case any rework is required because of contractors faulty erection and which is noticed during commissioning the same has to be rectified by the contractor at his cost.

1.16.46 Contractor to provide necessary commissioning assistance from precommissioning stage onwards and up to continuous operation of Gas turbine, GTG / STG and Auxiliaries. The category of personnel to be as per site requirement and to meet the various pre-commissioning and commissioning programmes made to achieve the schedule agreed with customer. 1.16.47 After synchronization, the commissioning activities will continue. It shall be the responsibility of the contractor to provide manpower including necessary consumables, hand tools and supervision as part commissioning assistance till handing over of sets to customer. 1.16.48 It is the responsibility of the contractor to provide necessary manpower, tools, tackles and consumable till the completion of work under these specifications including for trial operation, even if commissioning of GTG / STG and the other equipments is delayed due to reasons not attributable to the contractor.
VOLUME- I A
1.17.0 1.17.1 FINAL PAINTING
PART- I CHAPTER-XVII PAINTING
The scope of work shall also include supply and application of final painting of all the erected equipments as required and specified in the BHEL / Customer / Customer Consultants painting specification that forms the part of this tender for the components of GTG / STG BOP / auxiliaries and other equipments erected under the scope of this tender.
1.17.2 In the case of steel fabricated items, raw steel after fabrication has to be cleaned and subsequent painting to be carried out. 1.17.3 All the exposed metal parts of the equipments including piping, structures, hangers etc., wherever applicable after installation unless otherwise specified the surface protected, are to be first painted with at least one coat of suitable primer and required number of finish coats as indicated in the Painting Specification in TCC which matches the shop primer paint used, after thoroughly cleaning the dust, rust, scales, grease oil, and other foreign materials by wire brushing scrapping and chemical cleaning and the same being inspected and approved by BHEL engineers for painting. Afterwards the above parts shall be finished with as per the instructions of BHEL/Customer official. 1.17.4 All welded joints should be painted with anti-corrosive paint, once radiography and stress relieving works are over. 1.17.5 Normally Paint shall be applied by brushing as per the instruction of BHEL Engineer. It shall be ensured that brush marks are minimum. If needed and insisted either by BHEL / Customer in certain cases, spray painting has to be carried out within the Quoted rates. Spray painting gun and compressed air arrangement has to be made by the contractor himself within the Quoted rates. 1.17.6 Paint used shall be stirred frequently to keep the pigment in suspension. Paint shall be of the ready mix type in original sealed containers as packed by the paint manufacturer. No thinners shall be permitted. Paint manufacturers instructions shall be followed in method of application, handling, drying time etc., 1.17.7 The scope of painting includes application of colour bands, lettering the names of the systems equipments; tag Nos of valves, marking the directions of flow and other data required by BHEL within the quoted rate. 1.17.8 All surfaces shall be thoroughly cleaned, free from scales, dirt and other foreign matter. Each coat shall be applied in an even & uniform film free from lumps, streaks, runs, sags and uncoated spots. Each coat (Primer, intermediate, finish) shall have a minimum thickness of dry film thickness (DFT) in microns and the

DFT of finish paint shall not be less than the specified. Necessary instrument for measuring the thickness of paint applied is to be arranged by the contractor. 1.17.9 Finish coat paint, No of coat and DFT shall be as indicated in the painting specification enclosed in this tender / relevant BHEL document/ customers specifications. The painting specification which is forming part of this tender as in TCC shall be used as guidelines to be followed.
1.17.10 The actual colour to be applied shall be approved by the customer before starting of actual painting work. 1.17.11 Primer & finish paint shall be of reputed paint supplier approved by BHEL / Customer. Contractor has to procure paints from the BHEL / Customer approved agencies only, and the paints should be as per the customer painting specification. The quality of the finish paint shall be as per the standards of IS or equivalent as approved by BHEL / Customer. Before procurement of paint the contractor has to obtain the clearance from BHEL authorities. 1.17.12 No paint shall be applied when the surface temp is above 55 deg. Centigrade or below 10 deg. Centigrade, and when the humidity is greater than 90% to cause condensation on the surface or frost / foggy weather. 1.17.13 Before commencement of final painting, contractor has to obtain written clearance from BHEL / Customer for effective completion of surface preparation. 1.17.14 Before applying the subsequent coats, the thickness of each coat shall be measured and recorded with BHEL / Customer. 1.17.15 PRESERVATION / TOUCH UP PAINTING 1.17.15.1 Contractor shall carryout cleaning and preservation / touch up painting for the materials / equipments under this tender specification right from preassembly stage to till the equipment is cleared for final painting. 1.17.15.2 Any equipment which has been given the shop coat of primer shall be carefully examined after its erection in the field and shall be treated with touch up coat of red oxide primer wherever the shop coat has been abraded, removed or damaged during transit / erection, or defaced during welding. 1.17.15.3 Mostly the equipment / items/ components will be supplied as finish painted. However during storage and handling, the same may get peeled off / deteriorate. All such surfaces are to be thoroughly cleaned and to be touch up painted with suitable approved primer and finish paint matching with shop paint / approved final colour.
VOLUME IA PART II CHAPTER - 1 REVERSE AUCTION PROCEDURE

GENERAL TERMS AND CONDITIONS OF REVERSE AUCTION Against this NIT for the subject work, tender shall be processed through REVERSE AUCTION PROCEDURE i.e. ON LINE BIDDING on INTERNET. 1. 2. 3. 4. 5. For the proposed reverse auction, technically and commercially acceptable bidders only shall be eligible to participate. BHEL will engage the services of a service provider who will provide all necessary training and assistance before commencement of on line bidding on Internet. BHEL will inform the vendor in writing in case reverse auction, the details of service provider to enable them to contact and get trained. Business rules like event date, time, start price, bid decrement, extensions, etc. also will be communicated through service provider for compliance. Vendors have to fax the compliance form in the prescribed (provided by service provider) before start of Reverse auction. Without this the vendor will not be eligible to participate in the event. BHEL will provide the calculation sheet (e.g.: EXCEL sheet) which will help to arrive at Total Cost to BHEL. Reverse auction will be conducted on schedule date & time. At the end of reverse auction event, the lowest bidder value will be known on the network. The lowest bidder has to fax the duly signed filled-in prescribed format as provided on case-to-case basis to BHEL through service provider within 24 hours of action without fail.
6. 7. 8. 9.
10. During Reverse Auction, the process of reverse auction is unsuccessful then BHEL at its discretion may decide to call the L1 bidder of reverse auction for further negotiation. 11. Sealed bid reverse auction: The opening bid (in the initial auction) of the bidders shall be same as that quoted in their final sealed price submitted to BHEL. The bidder shall confirm in writing to BHEL that their opening bid in both cases shall be same as that quoted in their final sealed price bids submitted to BHEL against this NIT along with Technical bid.

12. BHEL reserves the right to cancel Reverse Auction (RA) without assigning any reasons and resort to considering the sealed bids submitted by vendor for processing and finalizing the tender. 13. Any variation between the on-line bid value and signed document will be considered as sabotaging the tender process and will invite disqualification of vender to conduct business with BHEL as per prevailing procedure.
14. In case BHEL decides not to go for Reverse auction procedure for this tender enquiry, the price bids and price impacts, if any already submitted and available with BHEL shall be opened as per BHEL standard practice. 15. Bids given by the bidders during the reverse auction process will be taken as an offer to execute the work. Bids once made by the bidder, cannot be cancelled/withdrawn and bidders shall be bound to execute the work as mentioned above at the final bid price. BHEL shall take appropriate action as the lowest bidder do not execute the contract as per the rates quoted by him.
VOLUME- I A
PART II CHAPTER 2 to 7 In next 67 pages as below:

Site weld data Insulation schedule Insulation volume Weight schedule-item wise Weight schedule material wise Job specification for shop & Field Painting 01 03 01 01 01 60
SITE WELD DATA GA202

MRPL 2x28.45 MW STG.
MATERIAL SIZE in SCHEDULE
PIPING
WO : 1019410200 NO OF WELDS
IBR
A106GrB A106GrB A106GrB A106GrB A106GrB A106GrB A106GrB 4 4 2 1.5 1 .75 .5 80 40 80 80 80 80 80 5 10 95 40 100 5 15
NON-IBR
A106GrB A106GrB A106GrB A106GrB A106GrB A106GrB A106GrB A106GrB A335GrP11 A335GrP11 SS SS SS SS SS SS SS SS SS SS SS SS 6 4 3 2 1.5 1 .75 .5 1 .75 14 12 10 8 6 4 3 2 1.5 1 .75 .5 40 40 40 40 80 80 80 80 80 80 10 10 10 10 10 10 10 10 40 40 40 40 25 80 50 55 5 210 10 20 55 5 20 5 20 5 115 80 45 25 15 35 5 20
PIPING & LAYOUTS GROUP POWER PLANT ENGINEERIN
PREPARED OM PRAKASH
CHECKED OM PRAKASH
APPROVED
DOC NO : 4-313-00-88884 Page 1 of 1
REV 00 05-SEP-10
SJH
NOTE : THIS DOES NOT INCLUDE STUB WELDING
INSULATION SCHEDULE
GA202
PIPING
WO : 1019410200

SL NO LINE OPER TEMP DegC PIPE SIZE in INS THK mm PIPE LEN m ELBOW ELBOW ELBOW LR SR 45 EQ TEE END CAP FL BL FL SQ FL VI NI TEMP STUB RD SIZE1 in
RD SIZE2 in
RD TEE
REDU CER
VALVE SIZE in
VALVE
1 1
GLAND STEAM PIPING 1 1/2"-AS-380-3101-B2A-IH 372 1.5 1 .5 90 90 75 100 75 65 60 60 90 90 90 60 9 18 3 8 4 2 1 .5 2 1 2 12 12 3 18 1 1 1 6 6 2 1 1 2 3 6 2 1 2 6 3 2 3 2 1.5 1 1 1 6 4 3 1 2 1.5 1 1 .5 6 5 1.5 1 .5 3 .5 1 1 1 1 1
6"-GS-380-3102/3103-A1A-IH
350
6 2 1.5 1 .5
4"-GS-380-3104-A1A-IH
350
4 4
4 5
4"-GS-380-3105-A1A-IH 1"-GS-380-3106-A1A-IH
350 350
4 1
2"-GS-380-3107-A1A-IH
350
2 1
75 60
18
2 2 2
2 1 2
CHIMNEY STEAM PIPING 2"-GS-380-3108-A1A-IH 2"-GS-380-3109-A1A-IH 338 338 2 2 75 75 6 12 2 3 2 2 4 4 2 2 1 1
PIPING & LAYOUTS GROUP POWER PLANT ENGINEERING
PREPARED OM PRAKASH
CHECKED OM PRAKASH
APPROVED SJH
DOC NO : 4-313-00-88882 Page 1 of 3
REV 00 05-SEP-10
INSULATION SCHEDULE
GA202
PIPING
WO : 1019410200

RD SIZE2 in
RD TEE
REDU CER
VALVE SIZE in
VALVE
3 4
4"-GS-380-3110-A1A-IH 2"-GS-380-3111-A1A-IH
200 200
4 4 1 .5
50 50 40 40 50 40 40
12 18 15 1 18
5 5 6
2 1 2 1
1 1 .5 2
4 4 .5
1 1 2
2"-GS-380-3112-A1A-IH
200
4 1 .5
1 1
.5
3 1
TURBINE WATER DRAIN PIPING 1"-DR-13K-001 439 1 .75 90 90 90 90 90 25 25 60 60 90 18 6 18 18 18 18 18 18 18 18 5 5 5 5 5 5 5 5 CHECKED OM PRAKASH 3 1 1 1 1 1 1 1 APPROVED SJH 1 1 1 1 1 1 1 1 .75 .75 .75 .75 .75 .75 .75 .75 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REV 00 05-SEP-10 1 1 1 1 1 1 1 1 5 3 1 .75 1 1 2
2 3 4 5 6 7 8 9
1"-DR-13K-002 1"-DR-11K-003 1"-DR-11K-004 1"-DR-11K-005 1"-DR-11K-006 1"-DR-11K-006 1"-DR-11K-006 1"-DR-11K-006
442 400 410 100 100 350 350 380 PREPARED OM PRAKASH
1 1 1 1 1 1 1 1
DOC NO : 4-313-00-88882 Page 2 of 3
INSULATION SCHEDULE
GA202
PIPING
WO : 1019410200

RD SIZE2 in
RD TEE
REDU CER
VALVE SIZE in
VALVE
4 1 5 1
VACCUME BREAKER PIPING 3"-VA-380-3113-A1A STEAM PIPING FOR AUX.TURBINE 2"-HS-3801282-D2A-IH 410 2 1 .75 .5 115 90 90 90 90 36 36 12 48 24 4 16 16 10 10 2 2 2 2 4 2 2 2 1.5 1 2 2 8 100 3 40 9 4 1 3 1
4"-HS-3801283-A2A-IH
320
RECORD OF REVISIONS
REV 00 DATE 05-SEP-10 DATE first submission
PREPARED OM PRAKASH
CHECKED OM PRAKASH
APPROVED SJH
DOC NO : 4-313-00-88882 Page 3 of 3
REV 00 05-SEP-10
INSULATION VOLUME ESTIMATION SHEET

PIPE SIZE (in) 6 4 4 3 2 2 1 1 1 1 .75 1.5 1.5 .5 .5 .5 PIPE OD (mm) 168.3 114.3 114.3 88.9 60.3 60.3 33.4 33.4 33.4 33.4 26.7 21.3 21.3 21.3 21.3 21.3 INSULATION THICKNESS (mm) 100 90 50 40 75 115 90 60 40 25 90 65 90 75 40 60 PIPE LENGTH (m) 21.14 40.92 53.41 10.11 39.58 39.84 143.61 57.2 15.64 37.14 18 1 60.59 3.06 2.26 6.06 INSULATION VOLUME (Cu.m) 1.78 2.37 1.37 .16 1.26 2.53 4.99 .99 .14 .16 .6 .02 1.9 .07 .02 .09
GA202 1019410200
JACKETING AREA (Sq.m) 24.47 37.85 35.98 5.36 26.17 36.35 96.33 27.57 5.57 9.74 11.7 .48 38.33 1.65 .72 2.69
TOTAL INSULATION VOLUME (Cu. m)
18.45
18.45
PIPE SIZE <= 14" PIPE SIZE >= 16"
TOTAL JACKETING AREA (Sq. m) :
360.96
360.96
PIPE SIZE < 12" PIPE SIZE >= 12" & <=36" PIPE SIZE > 36"
PIPING & LAYOUTS GROUP T&C ENGINEERING POWER PLANT ENGINEERIN
PREPARED OM PRAKASH
CHECKED OM PRAKASH
APPROVED
DOC NO : 4-313-00-88883 Page 1 of 1
REV 00 05-SEP-10
SJH
WEIGHT SCHEDULE - ITEM WISE

GA202
PIPING
WO : 1019410200

ITEM BFL-NONIBR BOLTMATL CAP-NONIBR ELBOWLR-IBR ELBOWLR-NONIBR EQTEE-IBR EQTEE-NONIBR FL-IBR FL-NONIBR GASKET HEXPLUG PIPE-IBR PIPE-NONIBR RDTEE-NONIBR REDUCER-IBR REDUCER-NONIBR TSTUB-NONIBR VI-IBR VI-NONIBR WASHER VALVES-MOTOR OPERATED VALVES-HAND OPERATED QTY 2 868 3 42 186 24 41 10 84 94 8 186 618 2 23 27 8 4 37 8
WEIGHT (Kg) 20 540 20 50 500 30 190 50 550 10 10 990 4820 10 20 40 10 10 20 10
PREPARED OM PRAKASH
CHECKED OM PRAKASH
APPROVED
DOC NO : 4-313-00-88886 Page 1 of 1
REV 00 05-SEP-10
SJH
WEIGHT SCHEDULE - MATERIAL WISE GA202

MATERIAL A105 A106GrB A234WPB A335GrP11 SS WEIGHT Kg 800 4100 400 200 2600
PIPING
WO: 1019410200
PREPARED OM PRAKASH
CHECKED OM PRAKASH
APPROVED
DOC NO : 4-313-00-88885 Page 1 of 1
REV 00 05-SEP-10
SJH
JOB SPECIFICATION FOR SHOP & FIELD PAINTING, SMMS DEPARTMENT CAPATIVE POWER PLANT PARADIP REFINERY PROJECT, IOCL
SPECIFICATION NO. A011-06-42-PT-G09, Rev.0 Page 1 of 60
JOB SPECIFICATION FOR SHOP & FIELD PAINTING SMMS DEPARTMENT CAPTIVE POWER PLANT
PROJECT : OWNER PMC JOB NO. : : :
PARADIP REFINERY INDIAN OIL CORPORATION LIMITED (IOCL) ENGINEERS INDIA LTD. A011
0 Rev. No
28-07-2009
ISSUED AS JOB SPECIFICATION BY SMMS DEPARTMENT Purpose
AS Prepared by
DR.DNW Checked by
RC Approved by
Date
Format No. 8-00-0001-F1 Rev. 0
Copyright EIL All rights reserved
JOB SPECIFICATION FOR SHOP & FIELD PAINTING, SMMS DEPARTMENT CAPATIVE POWER PLANT PARADIP REFINERY PROJECT, ICOL
Abbreviations: AS CS LTCS MS SS GI DFT WFT DM ID OD NB RCC IRN : : : : : : : : : : : : : : Alloy Steel Carbon Steel Low Temperature Carbon Steel Mild Steel Stainless Steel Galvanized Iron Dry Film Thickness Wet Film Thickness De-mineralized Internal Diameter Outside Diameter Nominal Bore Reinforced Cement Concrete Inspection Release Note
CONTENTS SL. NO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PAGE NO. General 4 Scope 4 Reference Codes & Standards 6 Equipment 6 Surface Preparation, Shop Primer, Coating Application & Repair and 7 Documentation Paint Materials 16 Paint Systems 21 Paint System for Corrosive Environment-Offsite Areas (Excluding Cooling 24 Tower Area & DM Plant Area) Paint System for Corrosive Environment-Unit Areas 25 Paint System for Highly Corrosive Environment-Unit & Offsite Areas of the 26 Plant with Corrosive Fumes like HCL, H2SO4, Water Impingement, Salty Water, Chloride & Water Mist, DM Plant Area, Cooling Tower Area Paint System for Carbon Steel and Low Alloy Steel Storage Tanks (External)27 All Areas (Units & Offsites) Paint System for Carbon Steel and Low Alloy Steel Storage Tanks (Internal); 28 All Areas (Units & Offsites) Coating System for External Side of Underground Carbon Steel Plant Piping 30 and Underground Tanks in All Areas Painting Under Insulation All Environments/All Areas (Units & Offsites) 31 Internal Protection of Carbon Steel Coolers/ Condensers. 32 Field Painting System for GI Towers/Non-Ferrous Tube Sheet 32 Shop and Field Painting system for ETP 33 Storage 34 Colour Code for Piping 34 Identification of Vessels, Piping etc. 43 Painting for Civil Defence Requirements 43 Inspection and Testing 43 Guarantee 45 Qualification Criteria of Painting Contractor 45 Procedure for Approval of New Paint Manufacturers 45 Annexure-I List of Recommended Manufacturers 47 Annexure-II List of Recommended Manufacturers Products 48 DESCRIPTION
11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0
1.0 1.1
GENERAL These technical specifications shall be applicable for the work covered by the contract, and without prejudice to the provisions of various codes of practice, standard specifications etc. It is understood that contractor shall carry out the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Engineer-In-Charge. Wherever it is stated in the specification that a specific material is to be supplied or a specific work is to be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any deviation from this standard without written deviation permit from appropriate authority will result in rejection of job.
1.2
2.0 2.1
SCOPE Scope of work covered in the specification shall include, without being limited to the following. This specification defines the requirements for surface preparation, selection and application of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures, external & internal protection of storage tanks for all services, MS Chimney with & without Refractory lining, MS Chimney with insulation and without insulation and Flare lines etc. The items listed in the heading of tables of paint systems is indicative only, however, the contractor is fully responsible for carrying out all the necessary painting, coating and lining on external and internal surfaces as per the tender requirement. Extent of Work The following surfaces and materials shall require shop, pre-erection and field painting: a. All uninsulated C.S. & A.S. equipment like columns, vessels, drums, storage tanks(both external & internal surfaces), heat exchangers, pumps, compressors, electrical panels and motors etc. All uninsulated carbon and low alloy piping, fittings and valves (including painting of identification marks), furnace ducts and stacks. All items contained in a package unit as necessary. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc. Flare lines, external surfaces of MS chimney with and without refractory lining and internal surfaces of MS chimney without refractory lining. MS chimney with insulation and without un-insulation. Identification colour bands on all piping as required including insulated aluminium clad, galvanised, SS and nonferrous piping.
2.1.1
2.2 2.2.1
b.
c. d.
e.
f.
g.
Identification lettering/ numbering on all painted surfaces of equipment/piping insulated aluminium clad, galvanized, SS and non-ferrous piping Marking / identification signs on painted surfaces of equipment/piping including hazardous service. Supply of all primers, paints and all other materials required for painting (other than Owner supplied materials) Over insulation surface of equipments and pipes wherever required. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. Painting of pre-erection/fabrication and Shop primer. Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the field/site before and after erection as required. All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP plant.
h.
i.
j. k.
l. m.
n.
2.2.2
The following surfaces and materials shall not require painting in general. However, if there is any specific requirement by the owner, the same shall be painted as per the relevant specifications: a. b. c. Uninsulated austenitic stainless steel. Plastic and/or plastic coated materials Non-ferrous materials like aluminum.
2.3 2.3.1
Documents The contractor shall perform the work in accordance with the following documents issued to him for execution of work. a. b. c. Bill of quantities for piping, equipment, machinery and structures etc. Piping Line List. Painting specifications including special civil defence requirements.
2.4
Unless otherwise instructed, final painting on pre-erection/ shop primed pipes and equipments shall be painted in the field, only after the mechanical completion, testing on systems are completed as well as after completion of steam purging wherever required. Changes and deviations required for any specific job due to clients requirement or otherwise shall be referred to EIL for deviation permit.
2.5
3.0 3.1
REFERENCE CODES & STANDARDS Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the contract, latest editions of the following codes and standards are applicable for the work covered by this contract. IS-5 : RAL DUTCH : IS-101 : IS-2379 : ASTM-Vol 6.01 & 6.03: ASA A 13.1-1981: Colour coding. International Standard for colour shade (Dutch Standard) Methods of test for ready mixed paints and enamels. Indian Standard for Pipe line identification-colour code. American standard test methods for Paints and Coatings. Scheme for identification of piping systems: American National Standards Institution.
3.2
Surface Preparation Standards The latest editions of any of the following standards shall be followed for surface preparation:
3.2.1
ISO 8501-1 / SIS-05 59 00: ISO standard for Preparation of steel substrates before application of paints and related products. This standard contains photographs of the various standards on four different degrees of rusted steel and as such is preferable for inspection purpose by the Engineer-In-Charge. Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPCSP). National Association of Corrosion Engineers, U.S.A., (NACE). Various International Standards equivalent to Swedish Standard for surface preparations are given in Table-I. The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards and codes at site. The paint manufacturer's instructions shall be followed as far as practicable at all times for best results. Particular attention shall be paid to the following: a. b. Instructions for storage to avoid exposure as well as extremes of temperature. Surface preparation prior to painting shall be followed as per Table 8.0 to 16.0 of this standard shall be followed. Mixing and thinning. Application of paints and recommended limit on time intervals in between
3.2.2
3.2.3 3.2.4
3.3
3.4
c. d. coats. 4.0 4.1
EQUIPMENT All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all equipments, scaffolding materials, shot & grit blasting equipments & air compressors etc. required to be used shall be suitable for the work and all in good order and shall be
arranged by the contractor at site and in sufficient quantity. The manufacturers test certificates / data sheets for all the above items shall be reviewed by Engineer-incharge at site before start of work. 4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack systems except that the Engineer-In-Charge may allow the hand mixing of small quantities at his discretion in case of specific requirement for touch up work only. SURFACE PREPARATION, SHOP PRIMER COATING APPLICATION & REPAIR AND DOCUMENTATION General In order to achieve the maximum durability, one or more of following methods of surface preparation shall be followed, depending on condition of surface to be painted and as instructed by Engineer-In-Charge. Adhesion of the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system. a. b. c. 5.1.2 Manual or hand tool cleaning. Mechanical or power tool cleaning. Blast cleaning.
5.0
5.1 5.1.1
Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per provisions of relevant tables given elsewhere in this specification The minimum acceptable standard in case of manual or hand tool cleaning shall be St. 2 or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blast cleaning it shall be Sa 2-1/2 as per Swedish Standard SIS055900(latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning shall be Sa 3 as per Swedish Standard in case of highly corrosive environment. Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to surface cleaning.
5.1.3
Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during humid weather conditions having humidity exceed 85%. Incase of internal coating of storage tanks, De-humidifiers shall be used to control the humidity levels during rainy season, if painting is to be carried out during the no rain days in case of exigency of project schedule with prior permission of Engineer-in-charge of OWNER/EIL Irrespective of the method of surface preparation, the first coat of primer must be applied by airless spray/ air assisted conventional spray if recommended by the paint manufacturer on dry surface. This should be done immediately and in any case within 4 hours of cleaning of surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall have the liberty to control the time period, at his sole discretion and/or to insist on re-cleaning, as may be required, before primer application is taken up. In general, during unfavorable weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.4
5.1.5
The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush. Acid etching with 10-15% HCL solution for about 15 minutes shall be carried and surface must be thoroughly washed with water to remove acid & loose particles and then dried completely before application of paint. Procedure of Surface Preparation : Air Blast Cleaning with abrasives The surfaces shall be blast cleaned using one of the abrasives like copper slag, A12O3 particles, chilled cast iron or malleable iron and steel at pressure of 7kg/cm2 at a appropriate distance and angle depending of nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size with appropriate size of G42 grade (maximum) and S250 grade size of steel shots (maximum) to obtain a desired surface profile of 35-50 microns trough to peak or specified profile in case of steel and malleable iron . The combination of steel grits and shots shall be normally in the ratio of 3 : 1. The quality of abrasives shall be free from contaminants and impurities and shall meet the requirements of SSPC AB1. Compressed air shall be free from moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from 3/16 to . On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic luster. Primer/first coat of paint shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns ). If possible vacuum collector shall be installed for collecting the abrasives and recycling.
5.2 5.2.1
5.2.2
Mechanical or Power Tool Cleaning Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or rotating steel wire- brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and /or washed by water or steam and thoroughly dried with compressed air jet before application of paint.
5.2.3
Manual or hand tool cleaning Manual or hand tool cleaning is used only where safety problems limit the application of other surface preparation procedure and hence does not appear in the tables of paint systems. Hand tool cleaning normally consists of the following: a. b. c. Hand de-scaling and/or hammering Hand scraping Hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering, scrapping tools, emery paper cleaning, wire brushing or combination of the
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved
above methods. On completion of cleaning, loose material shall be removed from the surface by clean rags and the surface shall be bushed, swept, dusted and blow off with compressed air/steam to remove all loose matter. Finally the surface may be washed with water and dried for effective cleaning. 5.3 Non-Compatible shop coat primer The paint system followed for Shop coating of structures/equipments etc., shall be mentioned in IRN. The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event of use of primer such as zinc Rich epoxy, inorganic zinc silicate etc. as shop coat, the paint system shall depend on condition of shop coat. If the shop coat is in satisfactory condition showing no major defect, the shop coat shall not be removed. The touch up primer and finishing coat(s) shall be identified for application by Engineer-in-Charge. 5.4 Shop coated (coated with Primer & finishing coat) equipment should not be repainted unless paint is damaged. Repair shall be carried out as per Table 7.2 of paint systems depending upon compatibility of paint. Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means of power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of field primer unless otherwise specified. If shop primer is not compatible with field primer then shop coated primer should be completely removed before application of selected paint system for particular environment. For Package units/equipment, shop primer should be as per the paint system given in this specification. However, manufacturers standard can be followed after review. Coating Procedure and Application Surface shall not be coated in rain, wind or in environment where injurious airborne elements exists, when the steel surface temperature is less than 5oF above dew point when the relative humidity is greater than 85% or when the temperature is below 40oF and when the ambient/substrate temp is below the paint manufacturers recommended temperature of application and curing. De-humidifier equipment shall be used to control RH and Dew point. The paint application shall not be done when the wind speed exceeds 20KM per hour. Blast cleaned surface shall be coated with one complete application of primer as soon as practicable but in no case later than 4 hrs the same day. To the maximum extent practicable, each coat of material shall be applied as a continuous film uniform thickness free of probes. Any spots or areas missed in application shall be recoated and permitted to dry before the next coat is applied. Applied paint should have the desired wet film thickness. Each coat shall be in proper state of cure or dryness before the application of succeeding coat. Material shall be considered dry for recoating when an additional coat can be applied without the development of any detrimental film irregularities, such as lifting or loss of adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval.
5.5
5.6
5.7 5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
When the successive coat of the same colour have been specified, alternate coat shall be tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage of the surface. The tinting material shall be compatible with the material and not detrimental to its service life and shall be recommended by the original paint manufacturer. Air spray application shall be in accordance with the following: a. The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied, and shall be equipped with suitable pressure regulators and gauges. The air caps, nozzles, and needles shall be those recommended by the manufacturer of the equipment for the material being sprayed. The equipment shall be kept in satisfactory condition to permit proper paint application. Traps or separators shall be provided to remove oil and condensed water from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show no condensed water or oil. Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous mechanical agitation. The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be high enough to properly atomize the paint but not so high as to cause excessive fogging of paint, excessive evaporation of solvent, or less by over spray Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other foreign materials are not deposited in the paint film. Any solvents left in the equipment shall be completely removed before applying paint to the surface being painted. f. Paint shall be applied in a uniform layer, with overlapping at the edge of the spray pattern. The spray patterns shall be adjusted so that the paint is deposited uniformly. During application, the gun shall be held perpendicular to the surface and at a distance which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be released at the end of each stroke. All runs and sags shall be brushed out immediately or the paint shall be removed and the surface repainted. Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brush, daubers or sheepskins shall be used. All nameplates, manufacturers identification tags, machined surfaces, instrument glass, finished flange faces, control valve items and similar items shall be masked to prohibit coating deposition. If these surfaces are coated, the component shall be cleaned and resorted to its original condition.
5.7.6
b.
c.
d.
e.
g.
h.
i.
j.
Edges of structural shapes and irregular coated surfaces shall be coated first and an extra pass made later. If spray gun shows choking, immediately de-choking procedure shall be followed.
k.
5.7.7
Airless spray application shall be in accordance with the following procedure: as per stesl structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic pressure rather than air atomization to produce the desired spray. An air compressor or electric motor is used to operate a pump to produce pressures of 1000 to 6000 psi. paint is delivered to the spray gun at this pressure through a single hose within the gun, a single paint stream is divided into separate streams, which are forced through a small orifice resulting in automization of paint without the use of air. This results in more rapid coverage with less over spray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray. Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have in built agitator that keep the paint uniformly mixed during the spraying. The unit shall consist of in built strainer. Usually very small quantity of thinning is required before spray. In case of high build epoxy coating (two pack). 30:1 pump ratio and 0.020-0.023 tip size will provide a good spray pattern. Ideally fluid hoses should not be less than 3/8 ID and not longer than 50 ft to obtain optimum results. In case of gun choking, de-choking steps shall be followed immediately.
5.7.8
Brush application of paint shall be in accordance with the following: a. Brushes shall be of a style and quality that will enable proper application of paint. Round or oval brushes are most suitable for rivets, bolts, irregular surface, and rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over five inches. Paint shall be applied into all corners. Any runs or sags shall be brushed out. There shall be a minimum of brush marks left in the applied paint. Surfaces not accessible to brushes shall be painted by spray, doubers, or sheepkin.
b.
c. d. e. f.
5.7.9
Manual application by sling (where 6 O clock position of pipe is not approachable) A canvas strip (alternatively a tinplate strip) about 450 mm wide and 1.5m long is hold under the pipe by two men holding this sling move it up and down and walk slowly forward while fresh coating is poured on the pipe and they manipulate the sling so that an even coating is obtained all round the bottom. This work shall be done very carefully and by experienced personnel. There shall not be any formation of Whiskers and holes in the coating. The coating film shall be inspected by mirror.
5.7.10
For each coat the painter should know the WFT corresponding to the specified DFT and standardize the paint application technique to achieve the desired WFT. This has to be ensured in the qualification trial. Drying of coated surfaces No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating when another coat can be applied without the development of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly deteriorated or mixing is faulty. No paint shall be force dried under conditions which will cause checking, wrinkling, blistering formation of pores, or detrimentally affect the conditions of the paint. No drier shall be added to a paint on the job unless specifically called for in the manufacturers specification for the paint. Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to the fullest extent practicable. Repair of damaged paint surface Where paint has been damaged in handling and in transportation, the repair of damaged coating of pre-erection / fabrication and Shop primer shall be done as given below and as per the Table 7.2 of this specification. Repair of damaged inorganic zinc silicate primer after erection / welding in the design temperature of -90oC to 550oC. Surface Preparation: Quickly remove the primer from damaged area by mechanical scraping and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the surface, if possible. Feather the primed surface over the intact adjacent surface surrounding the damaged area by emery paper. Primer coating: One coat of F-9 shall be applied wherever damaged was observed on pre-erection pre fabrication / shop primer of inorganic zinc silicate coating (F-9). F-9 shall not be applied if damaged area is not more than 5x5 cm.
5.8 5.8.1
5.8.2
5.8.3
5.8.4
5.9 5.9.1
5.9.2
5.10 5.10.1
Paint Application Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface (SSPC-SP-10) Shop priming/ pre-erection priming with F9 or F12 shall be done only with airless spray. For large flat surface field painting shall be done by airless spray otherwise brush can be used. Assessment of painting requirement
5.10.2 5.10.3
5.10.4
The paint system to be applied for a specific job shall be arrived at sequentially as given below: - Identify the environment from area classification details and chose the appropriate table. - Identify the design temperature from the technical documents - Identify the specific field paint system and surface preparation requirement from the above identified table and temperature range. - Identify the shop priming requirement from Table 7.1 based on compatibility of the above paint system. - Identify the need of repair of shop primer and execute as per Table 7.2. 5.11 5.11.1 5.11.2 Documentation A written quality plan with procedure for qualification trials and for the actual work. Daily progress report with details of weather conditions, particular of applications, no of coats and type of materials applied, anomalies, progress of work versus program. Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday detection, adhesion tests with signature of appropriate authority. Particulars of surface preparation and paint application during trials and during the work. Details of non-compliance, rejects and repairs. Type of testing equipments and calibration. Code and batch numbers of paint materials used.
5.11.3
5.11.4
5.11.5 5.11.6 5.11.7
TABLE-1 (FOR CLAUSE 5.0) SURFACE PREPARATION STANDARDS VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT) ISO 8501-1/ SSPC-SP, NACE, USA SIS-05 59 00 USA
SL. NO. 1
DESCRIPTION Manual or hand tool cleaning
REMARKS This method is applied when the surface is exposed to normal atmospheric conditions when other methods cannot be adopted and also for spot cleaning during maintenance painting.
Removal of loose rust, ST.2 loose mill scale and loose paint, chipping, scrapping, standing and wire brushing. Surface should have a faint metallic sheen Mechanical or power tool cleaning Removal of loose rust ST.3 loose mill scale and loose paint to degree specified by power tool chipping, de-scaling, sanding, wire brushing and grinding, after removal of dust, surface should have a pronounced metallic sheen. Dry abrasive Blast cleaning There are four common grades of blast cleaning SA 3 White metal Blast cleaning to white metal cleanliness. Removal of all visible rust. Mill scale, paint & foreign matter 100% cleanliness with desired surface profile. SA 2 Near white metal Blast cleaning to near white metal cleanliness, until at least 95% of each element of surface area is free of
SSPC-SP-2
--
SSPC-SP-3
--
3.1
SSPC-SP-5
NACE#1
Where extremely clean surface can be expected for prolong life of paint system.
3.2
SSPC-SP-10
NACE#2
The minimum requirement for chemically resistant paint systems such as epoxy, vinyl, polyurethane based and inorganic zinc
SL. NO.
DESCRIPTION all visible residues with desired surface profile.
VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT) ISO 8501-1/ SSPC-SP, NACE, USA SIS-05 59 00 USA
REMARKS silicate paints, also for conventional paint systems used under fairly corrosive conditions to obtain desired life of paint system. For steel required to be painted with conventional paints for exposure to mildly corrosive atmosphere for longer life of the paint systems.
3.3
Commercial Blast
SA 2
SSPC-SP-6
NACE # 3
3.4
Blast cleaning until at least two-third of each element of surface area is free of all visible residues with desired surface profile. SA 1 Brush-off Blast Blast cleaning to white metal cleanliness, removal of all visible rust, mill scale, paint & foreign matter. Surface profile is not so important
SSPC-SP-7
NACE # 4
6.0
PAINT MATERIALS Paint manufacturers shall furnish the characteristics of all paints materials on original printed literature, alongwith the test certificate for all specified characteristics given in this specification. All the paint materials shall be of first quality and conform to the following general characteristics as per the tables 6.1, 6.2, 6.3 and 6.4. PAINT MATERIALS TABLE No. 6.1 PRIMERS
Sl. DESCRIPTION No. 1 Technical name
P-2 Chlorinated rubber Zinc Phosphate primer. Single pack, air drying chlorinated rubber based medium plasticised with unsaponifiable plasticizer, pigmented with zinc phosphate. 40%. 30-40
P-4 Etch primer/wash primer Two pack polyvinyl butyral resin medium cured with phosphoric acid solution pigmented with zinc tetroxy chromate. 7-8% 8-10
P-6 Epoxy zinc phosphate primer Two component polyamine cured epoxy resin medium, pigmented with zinc phosphate.
P-7 ZINGA synthetic zinc primer One pack Synthetic Resin based zinc primer containing 96% of electrolytic zinc dust of 99.995% purity.
Type and composition
3 4
6 7 8 9 10
Volume Solids (minimum) DFT (Dry Film thickness) per coat (minimum) Theoritical covering capacity in M2/coat/ litre (minimum) Weight per litre in kgs/litre (minimum) Touch dry at 30oC (minimum) Hard dry at 30oC (maximum.) Overcoating interval Pot life at 30oC for two component paints (minimum) Temperature (Resistance (minimum)
40% 40-50
37% 40-50
8-10
8-10
8-10
4m/kg 2.67 kg at 15oC 10 minutes 24 hrs. Min.:4 hrs Unlimited 100oC.
1.3 30 minutes 24 hrs. Min.: 8 hrs Not Applicable 60 oC
1.2 2 hrs. 24 hrs. Min: 4-6 hrs.
1.4 After 30 min. 24 hrs. Min.:8hrs.
Not applicable 6 - 8 hrs. 80oC
11
NA
PAINT MATERIALS TABLE No. 6.2 FINISH PAINTS Sl. DESCRIPTION No 1 Technical name F-2 F-3 Chlorinated rubber based finish paint Single pack plasticised chlorinated rubber based medium with chemical and weather resistant pigments. F-6A/B Epoxy-High Build finish paint. F6A: Twopack polyamine cured epoxy resin medium suitably pigmented. F6B: polyamide cured epoxy resin medium suitably pigmented 62% 100-125 F-7 High build coaltar epoxy coating. Two pack polyamide cured epoxy resin blended with coaltar medium, suitably pigmented
Acrylic Polyurethane finish paint Type and composition Two-pack aliphatic isocynate cured acrylic finish paint.
3 4
6 7 8
Volume Solids (minimum.) DFT (Dry Film thickness) per coat (minimum) Theoritical covering capacity in M2/coat/litre (minimum) Weight per liter in kgs/litre(minimum) Touch dry at 30oC Hard dry at 30oC (max) Full cure at 30oC (for immersion/ high temperature service) Over-coating interval at 30 oC
40%. 30-40
40% 30-40
65% 100-125
10-13
8-10
5-6
5.2-6.5
1.3 1 hr. 16 hrs 5 days
1.2 30 minutes. 8 hrs NA
1.4 3 hrs. 16 hrs 5 days
1.5 4 hrs. 48 hrs. 5 days
Min.: 12 hrs.
Min.: Overnight
10
11
Pot life (approx.) at 6-8 hrs. 30oC for two component paints (minimum) Temperature 80 oC Resistance (minimum)
Min.: Overnight Max.: 5 days Not applicable 4-6 hrs
Min.: 24 hrs Max.: 5 days. 4-6 hrs.
60 oC
80oC
125oC.
PAINT MATERIALS TABLE No. 6.3 FINISH PAINTS Sl. DESCRIPTION No 1 Technical name F-8 Self priming type surface tolerant high build epoxy coating (complete rust control coating). Two pack epoxy resin based suitable pigmented and capable of adhering to manually prepared surface and old coating. F-9 Inorganic zinc silicate coating F-11 Heat resistant synthetic medium based two pack Aluminium paint suitable upto 250oC dry temp. Heat resistant synthetic medium based two pack Aluminium paint suitable upto 250oC. F-12 Heat resistant silicone Aluminium paint suitable upto 500oC dry temp.
Type & composition
3 4
6 7 8
9 10
11
Volume Solids (minimum) DFT (Dry Film thickness) per coat (minimum) Theoritical covering capacity in M2/coat/ litre (minimum) Weight per liter in kgs/litre (minimum) Touch dry at 30oC (maximum) Hard dry at 30oC (maximum) Full cure 30oC (for immersion /high temperature service) Over-coating interval Pot life at 30oC for two component paints (minimum.) Temperature Resistance (min)
72%. 100-125
A two pack air drying self curing solvent based inorganic zinc silicate coating with minimum 80% zinc content on dry film. The final cure of the dry film shall pass the MEK rub test. 60% 25% 65-75
Single pack silicone resin based medium with Aluminium flakes.
20% 20-25
20-25
6.0-7.2
8-9
10-12
8-10
1.4 3 hrs. 24 hrs 5days
1.2 3 hrs. 24 hrs NA
Min.: 10 hrs 90 minutes. 80 oC
Min.: 12 hrs.at 20oC & 50% RH 4-6 hrs. 400 oC
Min.: 24 hrs Not applicable 250oC
Min.: 24 hrs Not applicable 500oC.
PAINT MATERIALS TABLE No. 6.4 FINISH PAINTS Sl. DESCRIPTION No 1 Technical name F-14 F-15 F-16 Ambient temperature curing Poly Siloxane coating/High build cold applied inorganic copolymer based aluminium coating suitable for under insulation coating of CS and SS piping for high temperature service. Amercoat 738 from Ameron Products, USA/ Berger 938 from Berger Paints Ltd., or Intertherm 751 CSA from Akzo Nobel coating. Note: 6 F-17 Two component solvent free type high build epoxy phenolic/novala c epoxy phenolic coating cured with Polyamine adduct hardner system
Polyamine Twocured coal tar component epoxy Epoxy phenolic coating cured with Polyamine adduct hardner system (primer + intermediate coat + finish paint)
Type & composition
Specially formulated polyamine cured coal tar epoxy suitable for application under insulation
Two pack ambient temperature curing epoxy phenolic coating system suitable for application under insulation of CS/SS piping 65% 75-100 m
3 4
7 8
Volume Solids (minimum) DFT (Dry Film thickness) per coat (minimum) Theoritical covering capacity in M2/coat/ litre (minimum) Weight per liter in kgs/litre (mix paint) (minimum) Touch dry at 30oC (maximum) Hard dry at 30oC (maximum) Full cure 30oC (for immersion /high temp. service) Over-coating interval
70% 125 m
60% 75-100 m
Two component solvent free type high build epoxy phenolic/novala c epoxy phenolic coating cured with Polyamine adduct hardner system 98-100 % 125- 150 m
5.5
6.5- 8.5
6.0- 8.0
6.5 - 8
1.5
1.7
1.3
1.7
4 hrs 24 hrs 168 hrs (7 days)
1 hr 16 hrs -
Min. 6 hrs Max.5 days
Min.16 hrs Max. Not applicable
10
11
Pot life at 30oC for two component paints (minimum.) Temperature Resistance (min)
4 hrs
1.5 hrs
1 hr
1 hr
-45oC to 125oC under insulation
-45oC to 150oC under insulation (Note: 5)
Up to 400 deg. C for CS & SS surfaces under insulation
-45oC to 150oC for immersion service
NOTES (for tables 6.1 to 6.4): 1. Covering capacity and DFT depends on method of application. Covering capacity specified above are theoretical. Allowing the losses during application, min specified DFT should be maintained. All primers and finish coats should be cold cured and air drying unless otherwise specified.
2.
3. All paints shall be applied in accordance with manufacturer's instructions for surface preparation, intervals, curing and application. The surface preparation, quality and workmanship should be ensured. In case of conflict between this specification and manufacturers recommendation, the same shall be clarified through SMMS. 4. Technical data sheets for all paints shall be supplied at the time of submission of quotations. 5. F-15: Two-component Epoxy phenolic coating cured with Polyamine adduct hardner system (primer + intermediate coat + finish paint) suitable upto 225C (Intertherm 228 from M/s Akzo Nobel Coatings & Sealants, Bangalore). For all other companies, the temperature resistance shall be a maximum of 150C. 6. F-16: Ambient temperature curing epoxy poly siloxane Coating or high build cold applied inorganic co-polymer based aluminium coating. Amercoat 738 from Ameron Products USA/Kansai Nerolac Paints Ltd. Mumbai, suitable upto 400oC for CS surfaces and 600oC for SS surfaces. Berger 938 from Berger Paints Ltd Kolkata, suitable upto 400oC for CS & SS surfaces. Intertherm 751 from Akzo Nobel Coatings and Sealants Pvt Ltd, Bangalore, Inorganic co-polymer cold applied Aluminium spray coating suitable upto 400oC of CS & SS surfaces.
6.5
List of recommended Manufactures The paints shall conform to the specifications given above and best quality in their products range of manufacturers listed in Annexure-I.
7.0
PAINT SYSTEMS The paint system should be selected based on the areas classified inside the plant as given below. The Geographical corrosive and highly corrosive conditions of a plant located in Coastal and Marine area , Highly Corrosive conditions inside a plant and Industrial Corrosive Environment are taken care in the specifications in total. ENVIRONMENT/AREA CLASSFICATION Corrosive Environment-Offsite areas (excluding Cooling Tower area, DM-plant) Corrosive Environment-Unit areas Highly Corrosive Environment-Unit & Offsite areas of a plant with corrosive fumes like HCl, H2SO4, Water impingement, Salty water, , Chloride and water mist, Cooling Tower areas, DM Plant area.
Notes: 1. Painting systems (Primers, Finish Paints etc) based upon Area classification/ Environments (Corrosive / Highly Corrosive) / Applications are tabulated in Tables 8.0 to 16.0. 2. Primers & Finish paints covered in Tables 8.0 to 16.0 are listed in Table 7.1. 3. Repair of Pre-Erection/Pre-Fabrication & Shop priming after erection/ welding shall be done as per Table 7.2.
TABLE 7.1: LIST OF PRIMERS & FINISH COATS COVERED IN TABLE NOS. 8.0 - 16.0 PRIMERS P-2 P-4 P-6 P-7 Chlorinated rubber zinc Phosphate Primer Etch Primer/Wash Primer Two component Epoxy Zinc Phosphate Primer cured with polyamine hardner Single pack, synthetic resin based `ZINGA zinc primer containing 96% of electrolytic zinc dust in dry film.
FINISH COATS/PAINTS F-2 F-3 F-6A F-6B F-7 F-8 Two component Acrylic Polyurethane finish paint Chlorinated Rubber finish paint High Build Epoxy finish coating cured with polyamine hardner High Build Epoxy finish coating cured with polyamide hardner High build Coal Tar epoxy coating cured with polyamine hardner Self priming surface Tolerant High Build epoxy coating. cured with polyamine hardner F-9 F-11 F-12 F-14 F-15 Two component Inorganic Zinc Silicate coating Heat resistant synthetic medium based Aluminium paint Two component Heat resistant Silicone Aluminium paint. Specially formulated coaltar epoxy coating. cured with polyamine hardner Two component Epoxy phenolic coating cured with Polyamine adduct hardner system F-16 Engineered Epoxy poly Siloxane Coating or high build cold applied inorganic copolymer based aluminium coating F-17 Two component solvent free type high build epoxy phenolic/novalac epoxy
phenolic coating cured with Polyamine adduct hardner system
TABLE 7.2
REPAIR OF PRE-ERECTION/PRE-FABRICATION & SHOP PRIMING AFTER ERECTION/WELDING for all insulated and un-insulated CS, LTCS & low allow steel items in all environments. (refer clauses 5.4, 5.5 & 5.9) Surface Preparation SSPC-SP-3 Total DFT in Microns (min.) 1 coat of F-9 or 65-75 (F-9) 2 coats of P-7 @ or 40 DFT/coat 80 (P-7) Paint System
Sl. No. 7.1
Design Temp. in o C -40 to 150 for structures, hand rails and Gratings only -90 to 400 401 to 550
Remarks For few isolated damaged areas of more than 5x5 CM
7.2 7.3
SSPC-SP-3 SSPC-SP-3
1 coat of F-9 1 coat of F-12
65-75 20
-DO-DO-
NOTES: 1 The application and repair of pre-erection/pre-fabrication & Shop Priming given in above tables shall be done for all the items to be painted. In case the damages of primer are severe and spread on large areas, the Engineer-in-Charge may decide to advise reblasting and priming again if required. The pre-fabrication primer P-7, ZINGA primer is recommended as alternative repair primer to F-9 for Structures, Hand Rails and Gratings only. F-9 shall be used for all other areas.
TABLE 8.0 PAINT SYSTEM FOR CORROSIVE ENVIRONMENT-OFFSITE AREAS (excluding Cooling Tower area & DM Plant area) for external surfaces of Un-insulated Structures, Piping, Equipments, Pumps, Vessels etc (Note-1); (For Carbon Steel, LTCS & Low Alloy Steel) Paint system (Field) Surface Preparation & Design Temperatu Pre-erection/Shop Primer Finish paint re in oC Primer -90 to -15 SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat None Total Final DFT Remarks in Microns (min.) None 65-75 No overcoating to be done on F-9 as it will 2 coats of F-3 185 lead to mud @ 40 cracking. DFT/coat ; (2x40=80) F-3 paint 1 coat of F-6B 245 shall contain @ 100 pure DFT/coat + chlorinated 1 coat of F-2 @ rubber, not 40 DFT/coat; modified. (100+40=140) 3 coats of F-11 125 F-12 shall be @ 20 ambient DFT/coat; temperature (3x20=60) 2 coats of F-12 105-115 curing type @ 20 or 115Flare lines 125 DFT/coat shall be (2x20=40) or painted as 1 coat of F-16 per Table @ 50 9.0. DFT/coat. 2 coats of F-12 60 @ 20 DFT/coat (2x20=40)
Sl. No.
8.1
8.2
-14 to 60
1 coat of P2 @ 40 DFT/ coat 1 coat of P6 @ 40 DFT/ coat
8.3
61 to 80
8.4
81 to 250
SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat
None
8.5
251 to 400
None
8.6
401 to 550
SSPC-SP-10; 1coat of F-12 @ 20 DFT/coat
None
NOTES 1 The list of items given in the heading of the above table is not exhaustive. There may be more items for a particular contract where these specifications are used. The Contractor is fully responsible for completing painting including prefabrication primer for all the items supplied and fabricated through his scope of work as per tender document. For external surfaces of MS chimney with/without refractory lining and for internal surfaces of MS chimney without refractory lining 8.3, 8.4 & 8.5 shall be followed. For external surfaces of RCC chimney: 2 coats of F-6 @ 100 DFT/coat to obtain 2x100=200 DFT shall be applied after making surface preparation as per guidelines in 5.1.5.
If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not be repeated again in the field. In case the damages of primer are severe and spread over large areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table 7.2 In case of Paint systems as per Sl Nos 8.5 and 8.6, the colour bands shall be applied over the Aluminum paint as per the Colour coding requirement for specific service of piping given in Clause 18.0. PAINT SYSTEM FOR CORROSIVE ENVIRONMENT-UNIT AREAS for external surfaces of Un-insulated Structures, Piping, Equipments, Columns, Towers, Vessels, Pumps, Compressors, Blowers etc(Note1); (For Carbon Steel, LTCS & Low Alloy Steel) Total Final DFT Remarks in Microns (min.) No overSSPC-SP-10; None None 65-75 coating to be 1coat of F-9 @65done on 75DFT/coat SSPC-SP-10; 1 coat of P- 1 coat of F-6A 245-255 F-9 as it will lead to mud 1coat of F-9 @ 6 @ 40 @ 100 cracking. 65-75 DFT/coat DFT/ coat DFT/coat + 1 coat of F-2 @ 40 DFT/coat; F-12 shall be (100+40=140) SSPC-SP-10; None 2 coats of F-12 105-115 ambient 1coat of F-9 @ @ 20 or 115- temperature curing type 125 65-75 DFT/coat DFT/coat (2x20=40) or 1 coat of F-16 @50 DFT/coat. SSPC-SP-10; None 2 coats of F-12 60 1coat of F-12 @ @ 20 20 DFT/coat DFT/coat (2x20=40)
TABLE 9.0
Sl. No.
Paint system (Field) Surface Preparation & Design Temperatu Pre-erection/Shop Primer Finish paint Primer re in oC -90 to -15
9.1
9.2
-14 to 80
9.3
81 to 400
9.4
401 to 550
NOTES: 1. The list of items given in the heading of the above table is not exhaustive. There may be more items for a particular contract where these specifications are used. The Contractor is fully responsible for completing painting including prefabrication primer for all the items supplied and fabricated through his scope of work as per tender document. 2. If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not be repeated again in the field. In case the damages of primer are severe and spread over large areas, the engineer-in-charge may decide & advise re-blasting and
priming again. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table 7.2. 3. In case of paint systems as per Sl Nos 9.3 and 9.4, the colour bands shall be applied over the Aluminum paint as per the Colour coding requirement for specific service of piping given in clause 18.0. TABLE 10.0 PAINT SYSTEM FOR HIGHLY CORROSIVE ENVIRONMENT- UNIT & OFFSITE AREAS OF THE PLANT with corrosive fumes like HCl, H2SO4, Water Impingement, Salty Water, Chloride & Water Mist, DM Plant Area, Cooling Tower Area for external surfaces of Un-insulated Structures, Piping, Equipments, Towers, Columns, Vessels, Pumps, Compressors, Blowers etc(Note-1); (For Carbon Steel, LTCS & Low Alloy Steel) Total Final DFT Remarks in Microns (min.) None None 65-75 No overcoating to be done on 1 coat of P- 2 coat of F-6A 345-355 F-9 as it will lead to mud 6 @ 40 @ 100 cracking. DFT/ coat DFT/coat + 1 coat of F-2 @ F-12 shall be 40 DFT/coat; ambient (2x100+40=240 temperature ) None 2 coats of F-12 105-115 curing type @ 20 or 115125 DFT/coat 2x20=40 or 1 coat of F-16 @ 50 DFT/coat. None 2 coats of F-12 60 @ 20 DFT/coat; (2x20=40)
Sl. No.
Paint system (Field) Surface Design Preparation & Temperatu Pre-erection/Shop Primer Finish paint Primer re in oC SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat
10.1 -90 to -15
10.2 -14 to 80
10.3 81 to 400
SSPC-SP-10; 1coat of F-9 @ 65-75 DFT/coat
10.4 401 to 550
SSPC-SP-10; 1coat of F-12 @ 20 DFT/coat
NOTES:
1. The list of items given in the heading of the above table is not exhaustive. There may be
more items for a particular contract where these specifications are used. The Contractor is fully responsible for completing painting including prefabrication primer for all the items supplied and fabricated through his scope of work as per tender document.
2. If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same
shall not be repeated again in the field. In case the damages of primer are severe and spread over large areas, the engineer-in-charge may decide & advise re-blasting and
priming again. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
3. In case of paint systems as per Sl Nos 10.3 and 10.4, the colour bands shall be applied
over the Aluminum paint as per the Colour coding requirement for specific service of piping given in clause 18.0.
TABLE 11.0
PAINT SYSTEM FOR CARBON STEEL AND LOW ALLOY STEEL STORAGE TANKS (EXTERNAL) All areas (Units & Offsites) Paint system (Field)
Total Final Sl. DFT Remarks No. in Primer Finish paint Microns (min.) 11.1 All external surfaces of shell, internal surfaces of shell above maximum liquid level exposed to atmosphere, wind girders, appurtenances, roof tops of all above ground tank including top side of floating roof of open tank as well as covered floating roof tank and associated structural works, rolling and stationary ladders, spiral stairways, hand rails for all environments for crude oil, LDO, HSD, ATF, Kerosene, Gasolene, motor spirit, DM water, firewater, raw water, potable water, acids, alkalis, solvents and chemicals etc. should 11.1 -14 to 80 SSPC-SP- 1coat of F-9 @ 65- 2 coats of F-6A @ 345-355 F-6 be suitable .1 10; 75 DFT/coat + 100 DFT /coat + 1 for 1coat of P-6 @ 40 coat of F-2 @ 40 DFT/ coat; occasional DFT/ coat ; water (65/75+40=105/115 (2x100+40=240) immersion ) Surface Design Preparatio Temperatu n re in oC 11.1 81 TO 150 .2 SSPC-SP10; 1 coat of F-15 primer @ 80 DFT/ coat + 1 coat of F15 intermediate coat @ 80 DFT/coat ; (80+80=160) 1 coat of F-9 @ 65-75 DFT/ coat 1 coat of F-15 finish coat @80 DFT/ coat + 1coat of F-2 @ 40 DFT/ coat; (80+40=120) 280
11.1 151TO 500 .3
2 coats of F-12 @ 20 DFT/coat; (2x20=40) or 1 coat of F-16 @ 50 DFT/coat 11.2 External surfaces of bottom plate (soil side) for all storage tanks. 11.2 -14 TO 80 SSPC-SP- 1 coat of F-9 @ 3 coats of F-7@ .1 10; 65-75 DFT/ coat 100 DFT/coat (3x100=300)
SSPC-SP10;
105-115 OR 115-125
F-12 shall be ambient temperature curing type
365-375
F-7 should be suitable for immersion service of the products given
11.2 81 TO 150 .2
SSPC-SP10;
1 coat of F-15 primer @ 80 DFT/ coat + 1 coat of F15 intermediate coat @ 80 DFT/coat ; (80+80=160)
1 coat of F-15 finish coat @ 80 DFT/ coat
240
NOTES 1. If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not be repeated again in the field. In case the damages of primer are severe and spread over large areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table 7.2
TABLE 12.0
PAINT SYSTEMS FOR CARBON STEEL AND LOW ALLOY STEEL STORAGE TANKS (INTERNAL) All Areas (Units & Offsites) Paint system (Field)
Total Final Sl. DFT Remarks No. in Primer Finish paint Microns (min.) 12.1 Underside of floating roof, internal surface of cone roof, bottom plate, bottom course up to 1meter height, oil side surfaces of deck plates, oil side surfaces of pontoons, roof structures, structural steel, ladders, supports for storing crude oil, LDO, HSD and Gas Oil (Excluding white oil products) 12.1 -14 to 80 SSPC-SP- 1coat of F-9 @ 65- 2 Coats of F-6A @ 305-315 Note-2 .1 10 75 DFT/coat + 100 DFT/coat; 1coat of P-6 @ 40 (2x100=200) DFT/ coat ; (65/75+40=105/115 ) Surface Design Preparatio Temperatu n re in oC 12.2 Inside of bare shell of floating roof tanks and cone roof tanks for items mentioned in 12.1 2 coats DFT need 1coat of 12.2 -14 TO 80 SSPC-SP- 1coat of not be Phosphating .1 10 Phosphating measured treatment with treatment with reconciliation phosphating phosphating of Chemical chemical @ 10 chemical used shall be M/Litre of @ 10 M/Litre of done (Note : coverage coverage 4) 12.3 Floating / Cone roof tanks for petroleum products such as ATF, Gasoline, Naptha, Kerosene, Motor spirit, inside of bottom plate, bottom course upto 4 meters height inside shell, underside of floating roof and shell above maximum liquid level, oil side surfaces of deck plates, oil side surfaces of pontoons, support structures and ladders etc. 12.3 -14 to 80 SSPC-SP- 1 coat of F-9 @ 3 coats of F-6A @ 365-375 Note-2 .1 10 65-75 DFT/coat 100 DFT/ coat; (3x100=300) 12.4 Inside of Bare shell of floating/cone roof tanks for products mentioned in 12.3. 12.4 -14 to 80 SSPC-SP- 1 Coat of F-9 @ None 65-75 .1 10 65-75 DFT/Coat 12.5 Internal protection of fixed roof type storage tanks for potable water: Inside of shell, under side of roof and roof structure inside surface, bottom plate and structural steel works, ladders, walkways, platforms etc. 2 Coats of F-6B @ 280 Note-2 12.5 -14 to 80 SSPC-SP- 2 Coats of P-6 @ 100 DFT/ Coat; .1 10 40 DFT/coat; (2x100=200) (2x40=80) 12.6 D.M. (De-mineralized water) and hydrochloric acid (HCL): Internal shell, bottom plate & all accessories
12.6 -14 to 60 .1
12.6 .2
12.7 12.7 .1
12.8 12.8 .1
4.5MM Natural Rubber lining as per SMMS specifications 6-06204 240 61 to150 SSPC-SP- 1 coat of F-15 1 coat of F-15 10 primer @ 80 DFT/ intermediate coat coat @ 80 DFT/coat + 1 coat of F-15 finish coat @ 80 DFT/ coat; (80+80=160) EG(Ethylene Glycol) tanks (internal shell, bottom plate roof and all accessories) All SSPC-SP- None 3 coats of vinyl 225 10 chloride co-polymer Amercoat 23 @ 75 /Coat ; (3x75=225) Inside pontoon and inside of double deck of all floating roofs. -14 to 80 SSPC-SP- 1 coat of F-8 @ 1 coat of F-8 @ 200 3 100 DFT/coat 100 DFT/coat SSPC-SP10 None
For DM tanks without steam blanketing For DM tanks with steam blanketing
12.9 Internal surfaces of wet slop, amine, sour water , water draw off storage tanks 240 12.9 -14 TO 80 SSPC-SP- 1 coat of F-15 1 coat of F-15 .1 10 primer @ 80 DFT/ intermediate coat coat @ 80 DFT/coat + 1 coat of F-15 finish coat @ 80 DFT/ coat; (80+80=160) 12.1 Underside of floating roof, internal surface of cone roof, bottom plate, bottom course up to 0 4meter height, oil side surfaces of deck plates, oil side surfaces of pontoons, roof structures, structural steel, ladders, supports for storing Vacuum Residue, Fuel oil , dry slop and other high temperature hydrocarbon liquids. 375 Note:3 12.1 81 TO 150 SSPC-SP- 1 coat of F-17 1 coat of F-17 0.1 10 primer @ 125 intermediate coat DFT/ coat @ 125 DFT/coat + 1 coat of F-17 finish coat @125 DFT/ coat; (125+125=250) 12.1 Inside of Bare shell of floating/cone roof tanks for products mentioned in 12.10 1 12.1 81 TO 150 SSPC-SP- 1 coat of F-17 None 125 1.1 10 primer @ 125 DFT/ coat
NOTES 1. If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not be repeated again in the field. In case the damages of primer are severe and spread over large areas, the engineer-in-charge may decide & advise re-blasting and
priming again. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table 7.2. 2. F-6A/F6B should be suitable for immersion service of the products given. 3. This system can be used where maximum operating temperature is below 150oC and design temperature is upto 200oC. Cases of operating temperature > 150oC are not covered in this spec, such cases shall be covered in the job specifications. 4. The phosphating chemical shall be applied on blast cleaned surface inside the shell of carbon steel storage tanks at the time of erection. Incase, any corrosion is observed at the time of commissioning, 2 coats of the phosphating chemical shall be applied at the discretion of Engineer-in-charge.
TABLE 13.0
COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL PLANT PIPING AND UNDERGROUND TANKS IN ALL AREAS Paint system (Field)
Sl. No.
13.1 13.1 .1
13.2 13.2 .1
13.2 .2 13.3 13.3 .1 13.3 .2
13.3 .2
Total Final DFT Remarks in Primer Finish paint Microns (min.) Underground carbon steel plant piping ( Yard/ Over the Ditch Corrosion protection Coating) 4 mm 25 to 65 SSPC-SP- 1 coat of synthetic 1 layer of coaltar 10 fast drying primer tape coating @ 25 @ DFT/ coat 2mm +1 coat of synthetic fast drying primer 25 @ DFT/ coat +1 layer of coal tar tape coating @ 2mm /layer as per EIL Standard Spec.No 6-79-0011 Carbon steel plant piping (underground). 375 66 to 150 SSPC-SP- 1 coat of F-17 1 coat of F-17 10 primer @ 125 intermediate coat DFT/ coat @ 125 DFT/coat + 1 coat of F-17 finish coat @125 DFT/ coat; (125+125=250) 151 to 400 SSPC-SP- 1 coat of F-16 1 coat of F-16 250 10 primer @ 125 finish coat @125 DFT/ coat DFT/ coat External side of un-insulated underground storage tanks: -40 to 80 SSPC-SP- 1 coat of F-9 @ 3 coats of F-7 @ 365-375 10 65-75 DFT/ coat 100 DFT/coat (3x100=300) 375 81 to 150 SSPC-SP- 1 coat of F-17 1 coat of F-17 10 primer @ 125 intermediate coat DFT/ coat @ 125 DFT/coat + 1 coat of F-17 finish coat @125 DFT/ coat; (125+125=250) 151 to 400 SSPC-SP- 1 coat of F-16 1 coat of F-16 250 10 primer @ 125 finish coat @125 DFT/ coat DFT/ coat Surface Design Preparatio Temperatu n re in oC
TABLE 14.0
PAINTING UNDER INSULATION (ALL ENVIRONMENTS) All areas (Units & Offsites) for insulated Piping, Storage Tanks, Equipments etc (Note-1); (For Carbon Steel, LTCS, Low Alloy Steel & Stainless Steel)
Sl. No.
14.1 14.1 .1
14.1 .2
14.2 14.2 .1
14.2 .2
Total Final DFT Remarks in Microns (min.) Insulated carbon steel, LTCS and low allow steel Piping, Storage Tanks, Equipment etc over-45 to 125 SSPC-SP-10; None 2 coats of F-14 315-325 No coating to be or 1coat of F-9 @ @ 125 305-315 done on 65-75 DFT/coat DFT/coat; F-9 as it will (2x125=250) or lead to mud 3 coats of F-15 cracking. @ 80 DFT/coat ; F-12 shall be (3x80=240) 125 ambient 126-400 SSPC-SP-10; None 3 coats of Ftemperature 135 1coat of F-9 @ 12 @ 20 curing type 65-75 DFT/coat DFT/coat; (3x20=60) or 1 coat F-16 @ 60 DFT/coat Insulated stainless steel including Alloy-20 piping (Note:2) If the piping Below 0oC Aluminium sheeting with aluminium foil and Chloride free & to all minus mineral sealant coating barium chromate shall be applied. equipments temperatur are already e erected than None 1 coats of F-14 250 0 to 125 SSPC-SP-10 surface shall @ 125 (15-25 surface be prepared DFT/coat; profile) by cleaning 1 coat of F-14 @ with emery 125 DFT/coat paper and wash/flush 0 to 125 SSPC-SP-10 None 1 coat of F-15 240 with chloride (alternate) (15-25 surface intermediate free DM profile) coat @ 80 water 1 coat of F-15@ DFT/coat + 1 followed by 80 DFT/coat coat of F-15 wiping with finish coat @ organic 80 DFT/ coat; solvent (80+80=160) Paint system (Field) Surface Preparation & Design Temperatu Pre-erection/Shop Primer Finish paint Primer re in oC SSPC-SP-10; 1 coat of F-16@ 125 DFT/coat SSPC-SP-10; 1 coat of Amercoat 738 @ 125 DFT/coat None 1 coat of F16@ 125 DFT/coat 1 coat of Amercoat 738 @ 125 DFT/coat 250
14.2 121 to 400 .3 14.2 401 to 600 .4
None
250
Only Amercoat 738 is suitable for
250 None 1 coat of SSPC-SP-10 14.2 Cyclic Amercoat 738 1 coat of .5 service (@ 125 )196 to 480 Amercoat 738 @ DFT/coat 125 DFT/coat excepting (-)45 to 120 14.3 No painting is required for insulated monel, incoloy and nickel lines. NOTES
the temperature of 600 deg.C and cyclic temperature.
1. Refer Notes 1 & 4 of Table 8.0. 2. The blast cleaning abrasives for SS and Alloy steel surfaces shall be SS grits/shots or Aluminium oxide grits/shots. 3. For SS surfaces with cyclic temperature of -45 to125 deg.C, both 14.2.1 & 14.2.2 are applicable.
TABLE 15.0 INTERNAL PROTECTION OF CARBON STEEL COOLERS / CONDENSERS Water boxes, channels, partition plates, end covers and tube sheets etc. Paint system (Field) Surface Design Preparation & Temperatu Pre-erection/Shop Primer Finish paint Primer re in oC SSPC-SP-10; 1 coat of P-6 @ 40 DFT/coat SSPC-SP-3; 1 coat of P-4 @810 DFT/ coat+ 1coat of P-6 @ 40 DFT/coat. None Total Final DFT Remarks in Microns (min.) 2 coats of F-7 290 For CS @ 125 surfaces DFT/coat; (2x125=250) (Non ferrous 2 coats of F-7 300 and brass @ 125 tube sheets) DFT/coat; (2x125=250)
Sl. No.
15.1 Upto 65
15.2 Upto 65
None
TABLE 16.0 PAINTING SYSTEM FOR GI TOWERS/NON-FERROUS TUBE SHEET Paint system (Field) Surface Design Preparation & Temperatu Pre-erection/Shop Primer Finish paint re in oC Primer SSPS-SP-3 1 coat of P4 @8-10 DFT/ coat + 1 coat of P6 @ 40 DFT/coat 1 coat of P4 @ 8 DFT/coat.+ 1 coat of P6 @ 40 DFT/coat. Total Final DFT Remarks in Microns (min.) 2 coats of F-2 130 Shade as per @ 40 defence DFT/coat; requirements (2x40=80)
Sl. No.
16.1 Upto 65
16.2 Upto 65
SSPS-SP-3
2 coats of F-7 300 @ 125 DFT/coat; (2x125=250)
(Non ferrous and brass tube sheets)
17.0
SHOP & FIELD PAINTING SYSTEM FOR EFFLUENT TREATMENT PLANT Design Temperature in oC Paint System Primer Total DFT in Microns (min.) 365
Sl. No. 17.1
17.2
17.3
17.4
Finish Paint -14 to 80(for SSPS-SP-10 1 coat of F- 3 coats of 9 @ 65- F-6A C.S./M.S. items): @100 75 Screens, Walk way DFT/coat DFT/coat bridges, Baffles, 3x100=300 Dual media filters(external) Vertical pumps, piping in treated effluent sump and pump house, external side lining of Slop oil MS tank 265 -14 to 80(CS/MS SSPS-SP-10 1 coat of F- 2 coats of 9 @ 65- F-6A Items) for Vertical @100 75 pump and piping in, DFT/coat. DFT/coat Bio-sludge sump and pump, Filter feed sump and pump, Process sump, Sanitary sump; Transfer sump, Sludge, MS Slop oil tank internal, scrapping mechanism in Clarifier, Screw pump -14 to 80 deg.C :All Blast As per As per 3mm R.C.C. surfaces cleaning to SMMS-EIL SMMS-EIL such as tanks, SSPC-SP specificatio specification lines n for Epoxy s for Epoxy structures, drains guide Acid screed etc.) in Process and screed lining sump, TPI separator etching with lining No.6- as per (Process and Oil), 10-15% Hcl 06-209 6-06-209 (latest Aeration Tank, acid followed (latest Revision) Transfer sump etc. by thorough Revision) water washing. 4.5mm Rubber Upto 60 deg. C SSPC-SP-10 Lining as C.S/M.S Dual media per SMMSfilters (Internal), EIL Spec. Chemical dosing 6-06-204 tanks(internal such Rev.4 as DAP, Urea (Latest revision)
Surface Preparation
Remarks
Epoxy screed lining shall be used as per specific instructions from Engineerin-Charge at site.
18.0 18.1
STORAGE All paints and painting materials shall be stored only in rooms to be arranged by contractor and approved by Engineer-in-charge for the purpose. All necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent building. A signboard bearing the word PAINT STORAGE NO NAKED LIGHT HIGHLY INFLAMABLE shall be clearly displayed outside. Manufacturers recommendation shall be followed for storage of paint materials. PIPING COLOUR CODE: The following colour coding system has been made based on international standards like ASME/ ANSI, BS and Indian Standard.
19.0
19.1
IDENTIFICATION The system of colour coding consists of a ground colour and secondary colour bands superimposed over the ground colour. The ground colour identifies the basic nature of the service and secondary colour band over the ground colour distinguishes the particular service. The ground colour shall be applied over the entire length of the uninsulated pipes. For insulated lines ground colour shall be provided as per specified length and interval to identify the basic nature of service and secondary colour bands to be painted on these specified length to identify the particular service. Above colour code is applicable for both unit and offsite pipelines.
19.1.1 The following ground colour designation for identification of basic classification of various important services shall be followed: Post Office Red Off White/Aluminium Canary Yellow Dark Admiralty Grey Orange Oxide red Fire protection materials Steam (all pressures) Chemicals and dangerous materials Crude oil, lube oil Volatile petroleum products (motor spirit and lighter) Non-volatile petroleum products (kerosene and heavier, including waxy distillates and diesel, gas oil) Residual oils, still bottoms, slop oils and asphalts, fuel oil Water (all purities and temperatures) Air and its components and Freon
Black Sky blue Sea green
19.1.2 Secondary colours: The narrow bands presenting the secondary colour which identifies the specific service, may be applied by painting or preferably by use of adhesive plastic tapes of the specific colour. 19.2 COLOUR BANDS AND IDENTIFICATION LETTERING
19.2.1 The following specifications of colour bands shall be followed for identifying the piping contents, size and location of bands & letters. The bandwidth and size of letters in legends will depend to some extent upon the pipe diameter. Either white or black letters are selected to provide maximum contrast to the band colour. Bands usually are 50 mm
wide and regardless of band width, are spaced 25 mm apart when two bands are employed Table 1.0: Colour bands and size of lettering for piping: Outside diameter of Width of colour Size of legend letters pipe or covering in bands in mm in mm mm 19 to 32 200 13 38 to 51 200 19 64 to 150 300 32 200 to 250 600 64 Over 250 800 89 In addition, ground colour as per specified length should be provided on insulated piping for easy identification of nature of fluid, on which the colour bands should be painted for identification of each service. The length of the ground colour should be 3 times the width of normal band or 2 meters, whichever is suitable depending on the length of the pipe. Size of letters stenciled/ written for equipment shall be as given below: Column and vessel Pump, compressor and other machinery : 150 mm (Height) : 50 mm (Height)
In addition, the contents of the pipe and/or direction of flow may be further indicated by arrows and legend. If a hazard is involved it must be identified clearly by legend. 19.2.2 Colour bands: The location and size of bands, as recommended, when used, shall be applied to the pipe: - On both sides of the valves, tees and other fittings of importance. - Where the pipe enters and emerges from walls and where it emerges from road & walkway overpasses, unit battery limits. - At uniform intervals along long sections of the pipe. - Adjacent to tanks, vessels, and pumps. 19.2.2 For piping, writing of name of service and direction of flow for all the lines shall be done at following locations: 19.2.3 The letters will be in black on pipes painted with light shade colours and white on pipes painted with dark shade colours to give good contrast. 19.2.4 Only writing of service name shall be done on stainless steel lines. Precautions should be taken while painting by using low chloride content painting to avoid any damage to the stainless steel pipes. It is preferable to use adhesive plastic tapes to protect stainless steel pipes. 19.2.5 Colour band specification: a) Unit Area: Offsite Area:
Bands at intervals of 6.0 meters. Bands at intervals of 10.0 meters.

b) Each pipe segment will have minimum one band indication, irrespective of length. c) The bands shall also be displayed near walkways, both sides of culverts, tanks dykes, tanks, vessels, suction and discharge of pumps/ compressors, unit battery limit, near valves of line, etc. 19.3 For alloy steel/ stainless steel pipes and fittings in stores/ fabrication yard, color band (Minimum wide) should be applied along the complete length of pipe, bends/ tees, sidecurved surface (on thickness) of flanges as well as valves as per the metallurgy. 19.4 In case of camouflaging requirements of civil defence or any other location requirements, the same shall be followed accordingly. 19.5 The specification for application of the complete Piping identification colour code, including base and bands colours, are presented in the following table confirming to RAL colour shades of Dutch Standard: RECOMMENDED RAL COLOR CODE FOR PAINTING OF PIPING AND EQUIPMENTS
SR. No.
SERVICE
RECOMMNDED COLOR FOR PAINT SYSTEM
RAL COLOR CODE BASE COLOR BAND COLOR
HYDROCARBON LINES (UNINSULATED) 1 2 3 4 6 7 8 9 CRUDE SOUR CRUDE SWEET LUBE OILS FLARE LINES LPG PROPYLENE NAPTHA M.S. AV.GASOLINE (96 RON) GASOLINE (regular, leaded) GASOLINE (premium, leaded) GASOLINE (white) Dark Admiralty grey with 1 orange band Dark Admiralty grey with 1 red band Dark Admiralty grey with 1 green band Heat Resistant Aluminium Orange with 1 oxide red band Orange with 2 blue bands Orange with 1 green band Orange with 1 dark admiralty grey band Orange with 1 band each of green, white and red bands Orange with 1 black band Orange with 1 blue band 7012 7012 7012 9006 2011 2011 2011 2011 3009 5013 6010 7012 2011 3001 6010
2011 6010 9010 3001
2011 2011
9005 5013
11
12
Orange with 1 white band
2011
9010
13
14
16 17 18 19
21 22 23 24
GASOLINE (Aviation 100/130) GASOLINE (Aviation 115/145) N-PENTANE DIESEL OIL (White) DIESEL OIL (Black) KEROSENE HY.KEROSENE DISUFIDE OIL (EXMEROX) M.T.O DHPPA FLUSHING OIL LAB FS LAB RS
Orange with 1 red band
2011
3001
Orange with 1 purple band
2011
4006
Orange with 2 blue bands Oxide red with 1 white band Oxide red with 1 yellow band Oxide red with 1 green band Oxide red with 2 green bands Oxide red with 1 black band
2011 3009 3009 3009 3009 3009
5013 9010 1023 6010 6010 9005
26 27 28
LAB (Off. Spec) N-PARAFFIN HEAVY ALKYLATE BLOW DOWN, VAPOR LINE BLOWDOWN A.T.F. TOULENE BENZENE LAB PRODUCT FUEL OIL FULE OIL (Aromatic rich) ASPHALT SLOP AND WASTE OILS SLOP AROMATICS
Oxide red with 3 green bands Oxide red with 2 white bands Oxide red with 2 black bands Oxide red with 2 dark admiralty grey bands Oxide red with 3 dark admiralty grey bands Oxide red with 1 light grey band Oxide red with 1-blue band Oxide red with red band
3009 3009 3009 3009 3009 3009 3009 3009
6010 9010 9005 7012 7012 7035 5013 3001
29 30 31 32 33 34 35 36 37 38 39
Off white / Aluminum with 1Brown band Off white / Aluminum with 2 brown bands Leaf brown with 1 white band Leaf brown with 1 yellow band Leaf brown with 1 green band Leaf brown with 1 blue band Black with 1 yellow band Black with 2 yellow bands Black with 1 white band Black with 1 orange band Black with 2 orange bands
9006 9006 8003 8003 8003 8003 9005 9005 9005 9005 9005
8004 8004 9010 1023 6010 5013 1023 1023 9010 2011 2011
CHEMICAL LINES 40 TRI-SODIUM PHOSPHATE Canary yellow with 1 violet band 1012 5000
41 42 43 44 45 46 47 48 49 50
CAUSTIC SODA SODIUM CHLORIDE AMMONIA CORROSION INHIBITOR HEXAMETA PHOSPHATE ACID LINES RICH AMINE LEAN AMINE SOLVENT LCS
Canary yellow with 1 black band Canary yellow with 1 white band Canary yellow with 1 blue band Canary yellow with 1 Aluminum band Canary yellow with 2 black bands Golden Yellow with 1 red band Canary yellow with 2 blue bands Canary yellow with 3 blue bands Canary yellow with 1 green band Canary yellow with 1 smoke grey WATER LINES
1012 1012 1012 1012 1012 1004 1012 1012 1012 1012
9005 9010 5013 9006 9005 3001 5013 5013 6010 7031
51 52 53 54 55 56 57 58 59 60 61 62
RAW WATER INDUSTRIAL WATER TREATED WATER DRINKING WATER COOLING WATER SERVICE WATER TEMPERED WATER DM WATER DM WATER ABOVE 150F SOUR WATER STRIPPED WATER ETP TREATED WATER
Sky blue with 1 black band Sky blue with 2 signal red band Sky blue with 1 oxide red band Sky blue with 1 green band Sky blue with 1 light brown band Sky blue with 1 signal red brown Sky blue with 2 green bands Sky blue with 1 aluminum band Sky blue with 2 black bands Sky blue with 2 pearl white bands Sky blue with 2 blue bands
5015 5015 5015 5015 5015 5015 5015 5015 5015 5015 5015 5015
9005 3001 3009 6010 1011 3001 6010 9006 9005 1013 5013 3009
Sky blue with 2 oxide red bands
FIRE PROTECTION SYSTEM (ABOVE GROUND) 63 FIRE WATER FOAM & EXTINGUISHERS Post office red 3002
AIR & OTHER GAS LINES (UNINSULATED) 64 65 66 67 68 SERVICE AIR INSTRUMENT AIR NITROGEN FREON CHLORINE Yellow green with 1 signal red band Yellow green with 1 black band Yellow green with 1 orange band Yellow green with 1 yellow band Canary yellow with 1 oxide band 6018 6018 6018 6018 1012 3001 9005 2011 1023 3009
69 70 71
SO2 H2S GAS (Fuel)
Canary yellow with 2 white bands Orange with 2 red oxide bands Orange with 1 aluminum band Orange with 2 aluminum bands Orange with 2 signal red band Orange with 1 light green band
1012 2011 2011
9010 3009 9006
72 73 74
GAS (Sour) GAS (Sweet) HYDROGEN
2011 2011 2011
9006 3001 6021
STEAM AND CONDENSATE LINES (UNINSULATED) Off white / Aluminum with 1 9006 1023 yellow band 76 MP STEAM Off white / Aluminum with 1 9006 3001 red band 77 MLP STEAM Off white / Aluminum with 1 9006 2011 orange band 78 LP STEAM Off white / Aluminum with 1 9006 6021 light green band 79 CONDENSATE Sky blue with 1 white band 5015 9010 80 CONDENSATE Sky blue with 3 oxide red 5015 3009 ABOVE 150F band 81 BFW Sky blue with 2 red bands 5015 3001 Note: For all insulated steam lines, the colour coding shall be follow as given for uninsulated lines with the specified length of color bands. 75 HP STEAM
INSULATED HYDROCARBON PIPING 82 83 84 85 IFO SUPPLY IFO RETURN HPS BITUMEN 1Black ground colour with 1 yellow band in centre Black ground colour with 1 green band in centre Black ground colour with 1 red band in centre Black ground colour with 2 red bands in centre Black ground colour with 1 brown band in centre Black ground colour with 2 brown bands in centre 1 Black ground colour with 1 blue band in centre 1 Black ground colour with 2 blue bands in centre 9005 9005 9005 9005 1023 6010 3001 3001
86 87 88 89
CLO VB TAR VR AM (BITUMEN / VBU FEED) VR BH
9005 9005 9005 9005
8004 8004 5013 5013
90 91 92
VAC. SLOP SLOP CRUDE SWEET
93
CRUDE OUR
94
VGO / HCU
95
OHCU BOTOM / FCCU FEED
1 Black ground colour with 1 white band in centre 1 Black ground colour with 1 orange band in centre 1 Dark admiralty grey ground colour with 1 red band in centre 1 Dark admiralty grey ground colour with 1 orange band in centre 1 Oxide red ground colour with 2 steel grey bands in centre 1 Oxide red ground colour with 2 steel grey bands in centre
9005 9005 7012
9010 2011 3001
7012
2011
3009
7011
3009
7011
UNINSULATED EQUIPMENTS, TANKS AND STRUCTURES 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 HEATER STRUCTURE HEATER CASING VESSELS & COLUMNS HYDROGEN BULLETS LPG VESSELS SO2 VESSEL HEAT EXCHANGER FO TANK AND HOT TANKS ALL OTHER TANKS CAUSTIC / AMINE / ACID TANKS SOUR WATER OUTER SURFACE IN BOILER HOUSE COMPRESSORS AND BLOWERS PUMPS Electrical Equipment Indore Electrical Equipment Outdoor HAND RAILING STAIRCASE, LADDER AND WALKWAYS LOAD LIFTING EQUIPMENT AND MONORAILS ETC Steel grey Heat resistant aluminium Aluminium Pink Oxide red Canary yellow Heat resistant aluminium Black Aluminum / Off white Golden yellow Sky Blue Heat resistant aluminum Dark admiralty grey Navy blue Pebbel grey Blue grey Fluorescent yellow Black Leaf brown 7011 9006 9006 3014 3009 1012 9006 9005 9006 1004 5015 9006 7012 5014 7032 7031 1026 9005 8003
115 116 117
118
GENERAL STRUCTURE LOCAL PANEL FACE PANEL REAR SURFACE, FRAME WORK & MOUNTING PLATES MONORAIL
Dark grey Opaline green Pale cream
7031 6026 9001
Signal red
3001
PIPES AND FITTINGS OF ALLOY STEEL AND SS MATERIAL IN STORE 119 120 121 1 22 123 124 125 126 IBR 9Cr-1Mo 5Cr-0.5Mo 21/4Cr-1 Mo 11/4Cr- Mo SS-304 SS-316 SS-321 Signal red Verdigris green Satin blue Aircraft yellow Traffic Yellow Dark blue grey Dark violet Navy blue 3001 6021 5012 1026 1023 5008 4005 5014
SAFETY COLOUR SCHEMES 127 128 DANGEROUS OBSTRUCTION DANGEROUS OR EXPOSED PARTS OF MACHINERY Black and alert orange band Alert orange 9005 2008 2008
RAL COLOR CODING FOR PETROCHEMICAL COMPLEX
Sr. No.
SERVICE
RECOMMENDED COLOR FOR PAINT SYSTEM REFINERY PRODUCTS
RAL COLOR CODE BASE COLOR 2011 2011 2011 2011 2011 2011 9005 BAND COLOR 3009 5013 8004 5026 6035 5013 1023
1 2 3 4 5 6 7
NATURAL GAS PROPANE METHANE CYCLOHEXANE n-HEXANE ETHANE BLENDED FUEL OIL
Orange with 3 Oxide red bands Orange with 3 Blue band Orange with 1 Brown band Orange with 1 Pearl night blue band Orange with 1 Pearl green bend Orange with 4 Blue bands Black with 3 Yellow bands
8 9 10 11 12 13 14 15 16 17
ETHYLENE OXIDE POLYMER PELLETS & SLURRY HDPE PELLETS WAX GLYCOL BUTADIENE < 15% BUTADIENE 5 95% BUTADIENE > 95% ALDEHYDE SOLUTION OCTENE-1
Orange with 3 Green bands Brown beige with 1 white bands Brown beige with 2 white bands Oxide Red with 1 Pastel Green Band Canary yellow with 1 Pearl gentian blue Orange with 1 band Pastel Green band Orange with 2 Pastel Green bands Orange with 3 Pastel Green bands Sky blue with 1 orange band Orange with 1 Blue, 1 Black and 1 Blue band Orange with 2 Blue bands + 1 Black band Orange with 2 Oxford blue bands Orange with 2 Red band Orange with 2 White bands Canary yellow with 1 Blue lilac band Canary yellow with 2 Blue lilac band Canary yellow with 3 Blue lilac band Canary yellow with 3 Green band Canary yellow with 1 Sky blue band Canary yellow with 2 Green band Yellow green with 1 Blue band Oxide red with 2 Purple band CHEMICALS
2011 1011 1011 3009 1012 2011 2011 2011 5015 20 11 2011 5013 5013
6010 9010 9010 6019 5025 6019 6019 6019 2011 50 90 05 13 9005 5013 3001 9010 4005 4005 4005 6010 5015 6010 5013 4006
18 19 20 21 22 23 24 25 26 27 28 29
ETHYLENE PROPYLENE BUTENE -1 HEXANE MEG DEG TEG POLYGLYCOL GLYCOL / WATER SOLUTION DTA OXYGEN CYCLE GAS SYSTEM
2011 2011 2011 1012 1012 1012 1012 1023 1012 6018 3009
29 30 31 32
ISOPRENYL ALUMINUM MAGNESIUM ETHYLATE TITANIUM TETRA CHLORIDE SULPHURIC ACID
Canary yellow with 1 copper brown bands Canary yellow with 2 copper brown bands Canary yellow with 1 chocolate brown band Golden Yellow with 3 red bands
1012 1012 1012 1004
8004 8004 8017 3001
33 34 35 36 37 38 39 40 41 42 43 44 45 46
CALCIUM HYDROXIDE SODIUM CHLORIDE FERRIC CHLORIDE SODIUM BI SULFIDE CHLORINE DIOXIDE HYDRAZINE CARBON DIOXIDE CARBON MONOXIDE TEAL LIQUID PEROXIDE CATALYST LINE CO-CATALYST LINE EO / WATER SOLUTION BCWS / BCSWR
Canary yellow with 3 black bands Canary yellow with 1 white band Canary Yellow with 3 red oxide bands Canary yellow with 3 white bands Canary yellow with 1 orange band Canary yellow with 3 blue bands Orange with 4 Aluminum bands Orange with 3 Aluminum bands Dark admiralty grey with 2 white bands Canary yellow with 1 red and 1 blue band Canary yellow with 2 Red band Canary yellow with 3 Red band Sky blue with 3 Green bands Sky blue with 1 Brown Biege band WATER
1012 1012 1012 1012 1012 1012 2011 2011 7012
9005 9010 3009 9010 2011 5013 9006 9006 9010 5013 3001 3001 6010 1011
1023 3001 1023 1023 5015 5015
47 48 49 50 51
52 53 54 55 56
CYCLE WATERLEAN CYCLE WATERRICH JACKET WATER JACKET WATERBIOCIDE JACKET WATERCORROSION INHIBITOR CHLORINATED WATER BACK FLUSH WATER CUTTING WATER REFRIGERATED WATER WASTE WATER
Sky blue with 2 blue lilac bands Sky blue with 3 blue lilac bands Sky blue with 3 black bands Sky blue with 2 aluminum bands Sky blue with 3 aluminum bands
5015 5015 5015 5015 5015
4005 4005 9005 9006 9006
Sky blue with 1 green band Sky blue with 3 signal red bands Sky blue with 1 orange band Sky blue with 2 violet blue bands Sky blue with 2 Signal red bands INTERMEDIATES
5015 5015 5015 5015 5015
6010 3001 2011 5000 3001
57
MOTHER LIQUOR SOLUTION
Orange with 3 pebble grey bands
2011
7032
58 59 60 61 62 63
ADDITIVES SOLUTION DEACTIVATORS OFF GAS OFF GAS PLUS POLYMER RA SOLUTION DONOR
Pearl green with 2 white band Pearl green with 2 orange band Pearl green with 2 yellow band Pearl green with 2 Aluminum bands Pearl green with 2 oxide red bands Pearl green with 2 black bands STEAM
6035 6035 6035 6035 6035 6035
9010 2011 1023 9006 3009 9005
64 65 66
VHP MHP STEAM (20 KG / CM2 G) OTHER PROCESS LINES e.g. PROCESS STEAM, PROCESS CONDENSATE, PROCESS VENTS. DECOKING AIR RPG C6-C8 CUT C4 MIX C9+ CUT / FLUX OIL C4 PURGE / C4 MIX C9 CUT C7-C8 CUT C3 PP RECYCLE PLANT AIR AROMATIC LIGHT DISTILLATION C9+ OWS-OIL WATER SEWER CRWSCONTAMINATED RAIN WATER SEWER CRYOGENIC TANK (RCC)
Offwhite / Aluminium with 2 yellow band Off white / Aluminium with 3 yellow bands Light grey with 1Trafffic yellow band
9006 9006 7035
1023 1023 1023
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
Yellow Green with 1 Terrabrown band Orange with 1 Yellow Green band Orange with 1 terrabrown band Orange with 1 peral black berry band Orange with 2 grey Beige band Orange with 2 peral black berry Orange with 1 grey beige Orange with 2 terra Brown band Orange with 1 Sky blue band Orange with 1 water blue Yellow green with 1 peral light grey Black with 1 water blue Orange with 1 Solman pink band Orange with 3 grey beige Sky blue with 1 band of salmon orange Sky blue with 2 bands of salmon orange
6018 2011 2011 2011 2011 2011 2011 2011 2011 2011 6018 9005 2011 2011 5015 5015
8028 6018 8028 4012 1019 4012 1019 8028 5015 5021 9022 5021 3022 1019 2012 2012
83
Orange
2011
20.0 20.1
IDENTIFICATION OF VESSELS, PIPING ETC. Equipment number shall be stencilled in black or white on each vessel, column, equipment & machinery (insulated or uninsulated) after painting. Line number in black
or white shall be stencilled on all the pipe lines of more than one location as directed by Engineer-In-Charge, Size of letter printed shall be as below : Column & Vessels Pump, compressor & other machinery Piping 20.2 Identification of storage tanks: The storage tanks shall be marked as detailed in the drawing. 21.0 21.1 PAINTING FOR CIVIL DEFENCE REQUIREMENTS Following items shall be painted for camouflaging if required by the client. a. All Columns b. All tanks in Offsites c. Large Vessels d. Spheres Two coats of selected finishing paint as per defence requirement shall be applied in a particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge. Method of Camouflaging Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all matt finish). Dark Green Light Green Dark Medium Brown 5: 3: 2 The patches should be asymmetrical and irregular. The patches should be inclined at 30 to 60 to the horizontal. 150mm (high) 50mm (high) 40-150 mm
21.2
21.3 21.3.1
21.3.2 21.3.3
21.3.4 The patches should be continuous where two surfaces meet at an angle. 21.3.5 The patches should not coincide with corners. 21.3.6 Slits and holes shall be painted in dark shades. 21.3.7 Width of patches should be 1 to 2 meters.
22.0 22.1
INSPECTION AND TESTING All painting materials including primers and thinners brought to site by contractor for application shall be procured directly from manufactures as per specifications and shall be accompanied by manufacturer's test certificates. Paint formulations without certificates are not acceptable. Engineer-In-Charge at his discretion, may call for tests for paint formulations. Contractor shall arrange to have such tests performed including batch-wise test of wet paints for physical & chemical analysis as per clause 24.4 of relevant ASTM test method. All costs there shall be borne by the contractor.
22.2.
The contractor shall produce test reports from manufacturer regarding the quality of the particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet samples of paint at random for quality of same. Batch test reports of the manufacturer's for each batch of paints supplied shall be made available by the contractor. 22.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In particular, following stage-wise inspection will be performed and contractor shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows: (a) (b) (c) Surface preparation Primer application Each coat of paint
In addition to above, record should include type of shop primer already applied on equipment e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc. Any defect noticed during the various stages of inspection shall be rectified by the contractor to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, contractor shall be responsible for making good any defects found during final inspection/guarantee period/defect liability period as defined in general condition of contract. Dry film thickness (D F T)) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to owner, the extra coat should have prior approval of Engineerin-charge. 22.4 Primer Application After surface preparation, the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence of inspector nominated by Engineer-In-Charge. 22.5 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats, the thickness of each coat and complete coverage should be checked as per provision of this specification. This should be approved by Engineer-In-Charge before application of successive coats. The contractor shall provide standard thickness measurement instrument with appropriate range(s) for measuring. Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of sand blasting. Holiday detectors and pinhole detector and protector whenever required for checking in case of immersion conditions. 22.7 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat shall be checked by application of each coat of same paint on M.S.test panel. The thickness of paint on test panels shall be determined by using gauge such as 'Elkometer'. The thickness of each coat shall be checked as per provision of this specification. This shall be approved by Engineer-In-Charge before application of paints on surface of chimney.
22.6
22.8
At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert technical service at site as and when required. This service should be free of cost and without any obligation to the owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations. The contractor is responsible to arrange the same. Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday detection check of finish and workmanship. The thickness should be measured at as many points/ locations as decided by Engineer-In-Charge and shall be within + 10% of the dry film thickness, specified in the specifications.
22.9
22.10 The contractor shall arrange for spot checking of paint materials for Sp.gr., glow time (ford cup) and spreading rate. 23.0 23.1 GUARANTEE The contractor shall guarantee that the chemical and physical properties of paint materials used are in accordance with the specifications contained herein/to be provided during execution of work. QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR Painting contractor who is awarded any job for EIL, Projects under this standard must have necessary equipments, machinery, tools and tackles for surface preparation, paint application and inspection. The contractor mush have qualified, trained and experienced surface preparator, paint applicator, inspector and supervisors. The contractor supervisor, inspector, surface preparator and paint applicator must be conversant with the standards referred in this specification.
24.0
25.0
PROCEDURE FOR MANUFACTURERS
APPROVAL
OF
NEW
COATING
MATERIALS
AND
Following procedure is recommended to be followed for approval of new manufacturers. 25.2 The manufacturer should arrange testing of the coating materials as per the list of tests given in para 24.4 below from one of the reputed Government laboratories. Samples of coating materials should be submitted to the Govt. laboratory in sealed containers with batch no. and test certificate on regular format of manufacturers testing laboratory. The sampling shall be certified and sealed by a certifying agency. All test panels should be prepared by Govt. testing agency coloured photographs of test panels should be taken before and after the test and should be enclosed alongwith test report. Sample batch no. and manufacturers test certificate should be enclosed alongwith the report. Test report must contain details of observation and rusting if any, as per the testing code. Suggested Government laboratories are:
25.2
25.2
IICT, Hyderabad HBTI, Kanpur DMSRDE, Kanpur IIT, Mumbai BIS Laboratories UICT, Matunga, Mumbai RITES, Kolkata PDIL, Sindri NTH, Kolkata 25.2 Manufacturers should intimate the company, details of sample submitted for testing, name of Govt. testing agency, date, contact personnel of the govt. testing agency. At the end of the test the manufacturer should submit the test reports to the company for approval. The manufacturer(s) shall be qualified based on the results of these tests and other assessment and the companys decision in this regard shall be final and binding on the manufacturer. Test required for evaluation of acceptance of coating materials for onshore application. Test Density Dipping properties Film characteristics Drying time Flexibility Hardness Adhesion Abrasion resistance DFT/coat Storage Stability Resistance to Humidity for 2000 hrs. Salt spray 2000 hrs Accelerated Weathering % Zn in Dry film for Inorganic Zinc Silicate primer 25.2 25.2 ASTM Test Method D 1475 D 823
D 1640 D 1737/D 522 D 3363 D 2197 D 968/ D 1044 AS PER SSPC GUIDELINES D 1849
D 2247 B 117 D 822 G 53
Coating systems for panel test shall be decided after discussion with EIL. Clause No. 24.0 is for approval prior to award of the contract. In case any agency proposes for any fresh approval after award of work, the same shall have no time implications upon the contract.
ANNEXURE-I LIST OF RECOMMENDED MANUFACTURERS Indian Vendors 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Asian Paints (I) Ltd., Mumbai Berger paints Ltd., Kolkata Kansai Nerolac Paints Ltd., Mumbai ( including Ameron, USA Products ). Chugoku Marine Paints Pvt. Ltd., Mumbai Shalimar Paints Ltd., Kolkata Sigma Kalon Marine and Protective Coatings(India) Pvt Ltd, Mumbai. CDC Carboline Ltd., Chennai Premier products Ltd., Mumbai Coromandel Paints & Chemicals Ltd., Visakhapatnam Anupam Enterprises, Kolkata Grand Polycoats, Vadodata Bombay Paints Ltd., Mumbai Akzo Nobel Coatings and Sealants Pvt. Ltd., Bangalore Cipy Polyurethanes Pvt. Ltd., Pune Gunjan Paints Ltd., Ahmedabad Advance Paints Ltd., Mumbai VCM Polyurethane Paints (for polyurethane paints only) Jotun Paints India Pvt Ltd, Chennai(Singapore) Paladin Paints and Chemicals , Mumbai Chembond Chemicals Pvt Ltd , Navi Mumbai Aashish Coating Technologies Pvt. Ltd, Vadodara/Mumbai
Foreign Vendors 1. 2. 3. 4. 5. 6. 7. Sigma Kalon Protective Coatings, Singapore Ameron, USA Kansai Paints, Japan Hempel Paints, USA Valspar Corporation, USA Akzo Nobel/International Coatings, UK Jotun Paints, Singapore
The following are approved for specific materials only. 1.0 2.0 Mark-chem Incorporated, Mumbai (for phosphating chemicals only). ChemTreat India Ltd.( for Phosphating Chemical and glass flake filled coatings of M/s Atlas Chemicals Corporation, USA). Carolina equipment and supply Co., USA. Zinga Metall(Rozenstraat 4-Industrial Zone)-9810 EKE-Belgium, Indian Agent-Newkem, Mumbai-14 (for cold spray zinc coating)
3.0 4.0
ANNEXURE-II Sl. No LIST OF RECOMMENDED MANUFACTURERS PRODUCTS Manufacturers P2 P4 P6 F9 Name Chlorinated Etch Primer/ Epoxy Zinc Inorganic Rubber Zinc Ph Wash Primer Ph. Primer Zinc Silicate Primer Primer/ Coating ASIAN PAINTS ASIOCHLOR APCONYL APCODUR APCOSIL 605 (I) LTD. HB.ZN.PH.PRIM WP636 (PC335) HB.ZP. ER RO PC 168 PC433 BERGER LINOSOL HIGH BISON WASH EPILUX 610 ZINC ANODE PAINTS LTD. BUILD ZP PRIMER HB PRIMER 304 MZS PRIMER AMERON AMERCOAT 178 AMERCOAT DIMETCOTEPRODUCTS 71/ 385P 9FT CHEMBOND KEMCHLOR 201 KEMGALVA KEMOXY 301 KEMGUARD CHEMICALS GRIP A1 501 TUFFKOTE SHALIMAR CHLOROKOTE TUFFKOTE EPIGUARD ZILIKATE PAINTS LTD ZINC ETCH PRIMER ZINC PHOSPHATE PHOSPHATE PRIMER GREY PRIMER GREY SIGMA KALON SIGMA NUCOL SIGMA ETCH SIGMA SIGMAZINCINDIA PVT LTD, UNICOAT 7321 PRIMER (7185) COVER 256 158 (7412) CDC CARBOLINE CARBOZINC CARBOLINE 893 11 LTD. PREMIER P-15/3A U17/92 PRODUCTS U-16/92 ETHYL LTD. SILICATE INORGANIC ZINC CORAMANDEL COROCLORE CPC WASH COROPEX CPC PAINTS & CR HB.ZN.PH PRIMER EPOXY INORGANIC CHEMICALS PRIMER ZN.PH. HIGH ZINC LTD. BILD PRIMER SILICATE PRIMER ANUPAM ANUCHLOR ZP ANUPRIME-291 ANUPAM ANUZINC ENTERPRISES PRIMER ANLICOR A- 2001 TP EZP-500 GRAND GP GP PRIME 401 GP PRIME POLYCOATS CHLOROPRIME 402 601 BOMBAY PENTA CHLOR PENTOLITE PENTADUR ZINC-O-SIL 75 PAINTS LTD. HB PRIMER WASH PRIMER PRIMER 8530 8632 8520 HEMPEL HEMPA TEX HEMPELS GALVASOL MARINE PAINTS HIGHBUILD 4633 SHOP 1570 PRIMER E1530 AASHISH COATING TECHCopyright EIL All rights reserved
3 4 5
10
11
12
13
14
NOLOGIES 15 AKZO NOBEL PAINTS 16 PALADIN PAINTS 17 VCM POLYURETHAN E PAINTS 18 JOTUN PAINTS
VEGCHLOR HB PRIMER 1143
VEGWASH PRIMER 1181
INTERGARD 251 VEGPOX 1241ZP
INTERZINC 12/22 THERMOSIL1 362 ZINC
JOTA ETCH TWO PACK WASH PRIMER
19 KCC PRODUCTS (KOREA) 20. CHUGOKU MARINE PAINTS PVT. LTD. 21. KANSAI NEROLAC PAINTS LTD.
EPOXY CQ RESIST-86 SPECIAL ZINC PHOSPHATE PRIMER EZ 180(N)
CAMIDECK PRIMER
GALBONS HB
NEROLAC HB CR ZINC PHOSPHATE PRIMER
NEROLAC ETCH PRIMER
NEROLAC NEROSIL 118 EPOXY ZINC PHOSPHATE PRIMER
Sl. No
3 4 5
6 7
10 11
12
13.
LIST OF RECOMMENDED MANUFACTURERS PRODUCTS (Cont. ) Manufacturers F2 F3 F6A/B F7 Name AcrylicChlorinated High Build High Build Coal Polyurethane Rubber Epoxy Finish Tar Epoxy Finish Paint Finish Paint Paint Coating ASIAN PAINTS APCOTHANE ASIOCHLOR CF APCODUR APCODUR CF (I) LTD. CF676 (PC 1109) 621 (PC 319) HB COATING 651/655(PC PC 1262 131/471) BERGER BERGER LINOSOL EPLIUX 04 EPILUX 555 PAINTS LTD. ACRYLIC PU CHLORINATED AND 78 HB FINISH RUBBER HB EPOXY COATING COATING AMERON AMERCOAT AMERCOAT 515 AMERCOAT AMERCOAT 450GL 383 HS 78HB CHEMBOND KEMTHANE 411 KEMCHLOR 211 KEMOXY 324 KEMOXY 314 CHEMCIALS SHALIMAR SHALITHANE CHLORKOTE HB EPIGARD TL BIPIGARD CTE PAINTS LTD FINISH FINISH FINISH ZL BLACK HB POLYAMINE/ COAL TAR POLYAMIDE EPOXY COATING SIGMA SIGMADUR SIGMA NUCOL SIGMA SIGMACOVER COATINGS. GLOSS (7528) FINISH 7308 GUARD 720 300 (7472) CDC CARBOLINE 132 CARBOLINE CARBOCARBOLINE 191 MASTIC-14 LTD. PREMIER U3/92 CR-71, CR FINISH 42B/4A HIGH 350/3A, COAL PRODUCTS POLYURETHANE PAINT BUILD TAR EPOXY LTD. EPOXY COATING CORAMANDEL COROTHANE COROCLORE CR COROPEX COROPEX PAINTS & SUPER PU FINISHING EPOXY HB EPOXY COAL CHEMICALS FINISH COATING TAR COATING LTD. ANUPAM ANUTHANE ANUCHLOR HB DURACOAT- COROGUARD ENTERPRISES ENAMEL ENAMEL 6000 GRAND GP BOND 141 GP GP GUARD POLYGUARD POLYCOATS CHLOROGAURD HP234 CE 631 BOMBAY PENTATHANE FP PENTACHLOR PENTADUR PENTADUR PAINTS LTD. 4510 FB 4635 HB 5540/5520 COALTAR EPOXY 8518/6518 HEMPEL HEMPATEX HEMPADUR HEMPADUR MARINE HIBUILD 4633 HIGH BUILD 1510 PAINTS 5520 GA 1110 PU-UB GA701 HB
14. AASHISH COATING TECH 15 AKZO NOBEL COAITNGS
INTERTHANE 990 -
INTERGARD 966 / 410
INTERTUF 262 (TAR FREE TYPE)
16 PALADIN PAINTS 17 VCM POLYURETHA NE PAINTS 18 JOTUN PAINTS 19 KCC PRODUCTS (KOREA) 20. CHUKOGU MARINE PAINTS PVT LTD. 21. KANSAI NEROLAC PAINTS
VEGTHANE VEGCHLOR (ALIPHATIC) FP3140 PIPCOTHANE ALIPHATIC POLYURETHANE FINISH PAINT HARDTOP XP
VEGEPOX 3245/3562
VEGEPOX 4265
UNY MARINE
PENGUARD HB KOEPOX TOPCOAT HB ET 5740 EPICON MARINE FINISH HB NEROPOXY HB 262/6061
JOTAGUARD 85 EH 173
BISCON HB 2001/ACHB
NEROTHANE ENAMEL
NEROLAC HB CHLORINATED RUBBER ENAMEL
NEROLAC EPOXY COAL TAR POLYAMINE/P OLYAMIDE CURED.
Sl. No.
3 4 5
10 11 12
13.
14
LIST OF RECOMMENDED MANUFACTURERS PRODUCTS (cont. ) Manufacturers F8 F-11 F-12 F-15 Name Epoxy Mastic Heat Resistant Heat Resistant Two Pack Coating Surface Synthetic Silicone Ambient Tolerant Medium Aluminium Temperature Aluminium Paint Paint Curing Epoxy Phenolic Coating ASIAN PAINTS APCODOR CF ASIAN HR HR SILICONE (I) LTD. 640 ALUMINIUM ALUMINIUM PAINT (PC 300) PAINT (PC 189) BERGER PROTECTO FERROTOL HR LUMEROS HR BERGER PAINTS LTD. MASTIC ALUMINIUM SILICONE AL. EPOXY PAINT PAINT(HR/143) PHENOLIC COATING AMERON AMERLOCK 400 AMERCOAT 878 CHEMBOND KEMGUARD 555 KEMGUARD CHEMICALS 250HR LUSTOTHERM EPIGARD TL SHALIMAR EPIPLUS 556 HEAT HS SILICONE 543 HS PAINTS LTD RESISTING ALUMINIUM FINISH LUSTROL ALUMINIUM SIGMATHERM SIGMA SIGMA SIGMA HIGH PHENGUARD COATINGS. COVER 630 TEMPERATURE 540/SUPER THERMOVIT 930 SYSTEM (7428) RESISTANT EPOXY SYSTEM 600 UPTO 200OC CDC CARBO CARBOLINE CARBOLINE CARBOLINE MASTIC-15 1248 4674 LTD. PREMIER BH EPOXY PRODUCTS MASTIC LTD. 150B/150A CORAMANDEL SILVOTOL HR CPC SILICONE PAINTS & ALUMINIUM HR ALUMINIUM CHEMICALS PAINT PAINT LTD. ANUPAM ANUANUPAM HEAT ENTERPRISES MASTIC-102 GUARD. GRAND GP PRIME POLYCOATS GUARD 235 BOMBAY PENTADUR KANGAROO PENTHOLITE PAINTS LTD. MASTIC 5515 HHR ALUMINIUM HRR 4950 ALUMINIUM 4951 HEMPEL HEMPDUR 1708 MARINE PAINTS AASHISH GA700SPE COATING TECH
15 AKZO NOBEL COATINGS 16 PALADIN PAINTS
INTERSEAL 670HS VEGEPOX MASTIC 2285
INTERTHERM 891 VEG HR AL PAINT -
INTERTHERM 50
INTERTHERM 228
17 VCM POLYURETHA NE PAINTS 18 JOTUN PAINTS PRIMASTIC UNIVERSAL
VEG HHR AL PAINT 600 DEG C -
19 KCC EH 4158H PRODUCTS (KOREA) 20. CHUKOGU UMEGUARD J&N LTD. MT/SX 21. KANSAI NEROMASTIC NEROTHERM NEROTHERM NEROLAC 400 250 538 PAINTS LTD. Note : This list is subject to revision based on fresh approval/ re-approval/ deletion.
JOTUN AL PAINT SOLVELITT AL TANKGUARD HR 250 DEG.C SILICONE STORAGE PAINT QT 606
VOLUME- IA
PARTIII CHAPTER 1
Form No: F-A (Rev 00)
BACKUP GUARANTEE AGREEMENT (To be executed on Rs.100/- nonjudicial stamp paper) THIS AGREEMENT is made and executed on this _______ day of _______, between M/s _____________________(the First Party, i.e, the Bidder) a company incorporated under the Company's Act 1956, having its registered office at ________________________(hereinafter called the "Bidder", which expression shall include its successors, administrators, executors and permitted assigns) and (2) M/s ________________________, (the Second Party, i.e, the Backup Guarantor), a company incorporated under the Company's Act 1956, having its registered office at ________________________ (hereinafter called the Backup Guarantor", which expression shall include its successors, administrators, executors and permitted assigns). WHEAEAS the owner, M/s.Bharat Heavy Electricals Ltd, a Government of India undertaking, proposes to issue / issued an NIT (hereinafter referred to as the said NIT) inviting bids from the individual bidders for undertaking the work of __________________ ____________, at ______________________ (hereinafter referred to as the said works). WHEREAS the said NIT enables submission of a bid with a Backup Guarantee subject to fulfillment of the Qualification criteria and other tender conditions specified in the said NIT. AND WHEREAS M/s _____________________________ (The First Party, i.e, the Bidder) will submit its proposal in response to the aforesaid invitation to bid by the Owner for ______________________________________________ (as detailed in the Bid doc. no. < TENDER REF--------> ) AND WHEREAS M/s _______________________ (The First Party, i.e the Bidder) itself is meeting the qualifying requirements of financial criteria ____________________________________________ (as detailed in the NIT) and in order to fully meet the qualifying requirements of technical in NIT, this back-up agreement is being entered into with M/s __________________________ (The Second Party, the Associates) , who fully meet the balance part of the said works (_____________________________).
Page 1 of 3

WHEREAS the First Party and the Second Party are contractors engaged in the business of carrying out similar/various items of works. WHEREAS the two parties have agreed to constitute themselves into a backup guarantee agreement for the purpose of carrying out the said works, and that the Backup Guarantee will be continued till the completion of the works in all respects. The backup guarantor will undertake and complete the work in case the bidder fails to execute the subject work with the same terms and conditions of the subject tender. WHEREAS the parties have agreed to certain terms and conditions in this regard: NOW THEREFORE THIS AGREEMENT WITNESSETH AS FOLLOWS : 1. First and Second parties hereby constitute themselves into a Backup Guarantee for the purpose of bidding and undertaking the said works pursuant to the said NIT as hereinafter stated. 2. The First Party will be the Lead bidder and will be responsible for the entire works. BACKUP GUARANTEE AGREEMENT 3. The First Party shall undertake the following part(s) of work detailed in the NIT namely ______________________________________________________________ 4. The Second Party shall undertake to provide a backup guarantee to ensure smooth & proper completion of the following part(s) of work detailed in the said NIT namely _________________________________________________________________ 5. The parties hereby declare and confirm that each of them will fulfill the required minimum qualifying requirements as prescribed in the said NIT for the works agreed to be undertaken by them as stated here-in-above. 6. It is also agreed between the parties hereto that all of them shall be severally and jointly responsible for the completion of the said works as per the schedule. Further, if the Employer/Owner sustains any loss or damage on account of any breach of the contract(s), we(First party & Backup guarantor), severally and jointly undertake to promptly indemnify and pay such losses / damages caused to the Employer/Owner on their written demand without any demur, reservation, contest or protest in any manner whatsoever.
Page 2 of 3

7. The parties hereby agree and undertake that they shall provide adequate finances, suitable tools, plants, tractors, trailers, other transportation equipment, other tools & plants, measuring & monitoring equipments (MMEs), men and machinery etc. for the proper and effective execution of the works to be undertaken by them as specified here-in-above. 8. It is agreed between the parties hereto that all the consequences, liabilities etc., arising out of any default in the due execution of the said works shall be borne by the party in default, that is by the party in whose area of work the default has occurred, provided however, so far as M/s Bharat Heavy Electricals Limited is concerned, all the parties shall be liable severally and jointly. 9. The backup guarantor hereby ensures that they have submitted a BG equivalent to 10% of the bid amount in the prescribed format, valid for the duration of the tendered works in a SEALED cover superscribed asBG from Back up guarantor along with price bid (Volume II). A declaration certificate in his letter head to this effect is submitted by him to BHEL, duly signed along with the Techno Commercial bid.
IN WITNESS HEREOF the parties above named have signed this agreement on the day month and year first above written at __________(Place) .
WITNESS For (FIRST PARTY) 1. NAME 2. OFFICIAL ADDRESS
WITNESS For (SECOND PARTY) 1. NAME 2. OFFICIAL ADDRESS
[The successful bidder shall have to execute the "JOINT DEED OF UNDERTAKING in the format to be made available by BHEL at the time of submission of tender].
Page 3 of 3
VOLUME- IA
PARTIII CHAPTER 2
DECLARATION
BACKUP GUARANTOR DECLARATION
(THIS DECLARATION CERTIFICATE IN HIS LETTER HEAD WITH DULY SIGNED AND ENCLOSED IN THE BIDDERS TECHNICAL OFFER).
I / WE_____________________(BACKUP GUARANTOR) DECLARES THAT A BANK GUARANTEE BEARING NO:_______________________________,DT:__________ FOR 10% OF THE BID AMOUNT TOWARDS______________________________VALID UPTO______________FROM_______________(BANK) IS ENCLOSED WITH PRICE BID (VOLUME II).WE CONFIRM THAT WE HAVE PROVIDED BACKUP GUARANTEE FOR THIS TENDER IN THIS PROJECT TO ANY OTHER BIDDER.
FOR AND BEHALF OF M/S___________
(SIGNATURE WITH OFFICIAL SEAL) Note: The tender will be liable to be rejected if the requisite BG is found to be not enclosed in the Price bid by the bidder.

BIDDERS DECLARATION
(THIS DECLARATION CERTIFICATE IN HIS LETTER HEAD WITH DULY SIGNED AND ENCLOSED IN THE BIDDERS TECHNICAL OFFER).
I / WE ___________________________________________________________ DECLARE THAT WE GONE THROUGH THE TENDER CONDITIONS AND ACCORDINGLY WE SELECTED THE BACKUP GUARANTOR M/S___________________________________________________________________ WHO IS FULFILLING THE STIPULATED QUALIFICATION REQUIREMENT IN THE TENDER AND WHOSE QUALIFYING EXPERIENCE DOCUMENTS ARE ENCLOSED IN OUR OFFER.
FOR AND BEHALF OF M/S___________
(SIGNATURE WITH OFFICIAL SEAL) Note: The tender will be liable to be disqualified if the required documents of the backup Guarantor is found to be not enclosed in the offer.

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TENDER SPECIFICATION

BHEL: PSSR: SCT: 1452

BHARAT HEAVY ELECTRICALS LIMITED

ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35 Date:

Rev 00 6th July 2010

NOTICE INVITING TENDER

Bharat Heavy Electricals Limited

Ref: BHEL PSSR SCT 1452

Date: Mar 17, 2011

NOTICE INVITING TENDER (NIT)

xii Latest updates

Not applicable Applicable

8 Copy of PAN Card submitted

DATE: AUTHORISED SIGNATORY (With Name, Designation and Company seal)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

VOLUME IA Part I & II TECHNICAL CONDITIONS OF CONTRACT (TCC)

BHARAT HEAVY ELECTRICALS LIMITED

TECHNICAL CONDITIONS OF CONTRACT (TCC) CONTENTS

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

Sl.No 1.3.1.1.0 1.3.1.1.1

Chargeable basis at the prevailing rate. Yes

Yes Yes Yes Yes

1.3.1.2.1.1 Single point source

TECHNICAL CONDITIONS OF CONTRACT (TCC)

Yes Yes Yes Yes

Chargeable basis at the prevailing rate. Yes

TECHNICAL CONDITIONS OF CONTRACT (TCC)

1.3.1.5.0 1.3.1.5.1 1.3.1.6.0 1.3.1.6.1

Scope to be taken care by BHE Bid L der

TECHNICAL CONDITIONS OF CONTRACT (TCC)

1.3.2.1.4 1.3.2.1.5 1.3.2.1.6 1.3.2.1.7 1.3.2.1.8

Yes Yes Yes Yes Yes

For daily monitoring meeting at site

Yes Not applicable

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

VOLUME- I A PART I CHAPTER IV

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

VOLUME- I A PART I CHAPTER - V

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC) VOLUME- I A PART I CHAPTER-VII TERMS OF PAYMENT

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

1.8.0 TAXES 1.8.1

Value Added Tax (VAT) for the works

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

VOLUME- I A PART I CHAPTER - IX WEIGHT SCHEDULE

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

TECHNICAL CONDITIONS OF CONTRACT (TCC)

19 C02 Rack - Frames 1

TECHNICAL CONDITIONS OF CONTRACT (TCC)

3350 1.2 x 1.5 x 3.5